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 | |
| Material Finish | N/A | |
| Industry for Use | Commercial Construction | |
| Volume | 60 | 000 annual |
| Lead Time | Same day | |
| Delivery Location | Midwest | |
| Standards Met | LEED | |
| 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 |