Case Study: Cost Reduction

Commercial Sensor Light

Case Study: Cost Reduction

A globally recognized LED navigation and high-performance lighting company used the expertise of Gait’s Design for Manufacturing Engineering team, to achieve thousands of dollars in monthly cost savings as well as speeding up their entire manufacture and testing process.

The Opportunity:
A major manufacturer, supplying over 60 countries worldwide, was dealing with significant quality issues on the diecast housing on one of their high-volume products. These quality issues were leading to increased costs and additional time and resources being spent during assembly.

This company had initially contacted Gait to explore opportunities for them to de-risk their supply chain by exploring alternative supply solutions. Further understanding the breadth and expertise of the Gait team, they immediately saw an opportunity for them to save time and money as well as securing a more diverse supply chain.

The company expected to reduce their costs by working with Gait on a process review and redesign.

The Solution:

In-depth Product and Production Review:
Gait’s Design for Manufacture Engineering team looked at the product from a fresh perspective. They looked at how it was currently manufactured, the materials that were being used and the testing process currently being employed.

Re-design:
As a first step, the Gait team redesigned the tooling. By carrying out this work, they were able to reduce the quality issues during the casting process.

Process-Enhancement:
Next, the team looked at implementing a post coating process. This ensured that the housing was completely sealed to avoid leaks.

Quality Control:
Finally, Gait designed and built a submersible test jig which allowed them to perform a 100% leak test on the housing units.

The Results:

Reduced Product Cost: 
The tooling price and the unit price of the product have been significantly less than costs prior to the process redesign by the Gait team.

Increased Product Performance:
The company experienced zero quality issues since transitioning to the new production process.

Reduced Resources:
They now have an efficient production process with absolutely no re-work required.