A cost reduction case achieved by transforming excess quality products into optimally shaped quality products.
We will expose excessive quality and carry out improvements (optimization tolerances). By representing quality optimization in drawings and shapes, we can derive cost reductions.
■Introduction of methods for quality optimization based on specifications, enabling cost reduction through a review of optimal shapes. ■Improving quality, delivery time, and price is also important to tackle through case studies! The first step begins from this site. ■What is necessary when setting tolerances to reduce defect rates? There are various methods to mitigate defect rates. This image is one of them. However, it is important to note that this method may lead to increased costs. Key Point: Setting tolerances optimized for processing is crucial. ■Original design pursuing ease of integration, improvement measures focusing on processability. Original type: The bearing is supported at the shoulder part that narrows from the center of the shaft. ■Improved type: The shaft is made straight, and the bearing is supported at the holder side. Key Point: It is important to choose shapes with low processing costs. ■As an issue: As a result of clarifying the causes of frequent defects, advice was given that establishing a step on the shaft for assembly would reduce defects more than determining the tolerances for the bearing support part from the holder side of the processor, leading to this shape.
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basic information
I believe it is important to recheck the gap between the improvements on the processing side and the original improvement measures as a countermeasure to turn excessive quality products into optimally shaped products. Aligning the bearings at the shoulder of the shaft, I recognize that using a loose tolerance instead of press-fitting the bearings on the holder side to reduce defects is not a proper approach, and I chose to replace the shaft with a straight design. This is an introduction to a horizontal development that contributes to cost reduction by constructing an optimal shape considering processability and tolerances.
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Applications/Examples of results
■Label printing machine manufacturer ■Medical device manufacturer ■Semiconductor manufacturing equipment peripheral device manufacturer ■Labor-saving machinery manufacturer ■Industrial equipment manufacturer ■Welfare equipment manufacturer ■Meat processing machinery manufacturer ■PC peripheral device manufacturer ■Information equipment manufacturer ■Amusement facility equipment manufacturer ■Power supply box manufacturer This is a method that can accommodate units from various industries. Please feel free to 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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