When our customer saw our redesign, which cut their part cost nearly in half, they immediately said yes–and swore us to secrecy. That’s why you won’t see a photo or product description here.
Beginning with a 22 gauge component that the customer was post-painting, we value-engineered a new, one-piece design with a proprietary forming and fastening system that eliminated welds. The new design enabled gauge reduction to 24, a one-pound weight reduction per part. A pre-painted finish eliminated powder coating. The product, completed in a single work cell with fewer steps, added $200,000 a year to the customer’s bottom line.
|Product Description||Black Box Capabilities Applied/Processes; Engineer; design; prototype; custom equipment and tooling|
|Tightest Tolerance||.005" (Hole Diameter)|
|Material Thickness||.050"24 GA(.023")|
|Material Used||Pre-painted G40 Galvanized|
|Industry for Use||Commercial Construction|
|Lead Time||Same day|
|Product Name||Black Box|
|Project Scope||Reduced material gauge; eliminated welding; eliminated painting; developed work-flow center to reduce inventory and labor|
|Design Work||Material selection; custom equipment and tooling; manufacturing design|