Cost reduction design examples for multiple product reduction strategies through integration via loss reduction and casting.
The original cost reduction strategy involves converting to lost-wax casting and casting, and reducing the number of parts through the integration of multiple components is effective. This is an example of standard parts reduction and integration. The image shows three parts that are bolted and welded together to form an arm. This shape is acceptable for small lots or one-off items. However, when there is a need for a certain volume of repeated production, it becomes necessary to adopt a shape that considers cost reduction. ONE POINT: It is optimal to integrate multiple parts of different shapes while leaving unnecessary surfaces in their cast state without further processing.
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【Before Improvement】 ● Each part processed with SS41 was fastened with screws. 【After Improvement】 ● Integrate each part and replace it with a cast FC20. There is an advantage of easy production during prototyping, but during mass production, even if it's a small quantity, consolidating several items for casting can significantly reduce costs. ○ For more details, please contact us.
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In the process of improving design, we analyze the entire structure of the equipment, making it possible to solve all issues related to quality, delivery time, and cost. In terms of cost reduction, we achieve an average cost reduction of 40-50% (only applicable to machined products). In our past maximum achievement, we achieved an 80% cost reduction. Our company directly conducts value analysis and improvement design for our customers' equipment.
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