[Case Study] Achieving Reduction in Processing Costs and Man-Hours

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last updated：Feb 17, 2021

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Introduction of a case where design changes and the introduction of a panel bender achieved a reduction in processing costs and man-hours!

The sheet metal division of major building materials manufacturer Company A was considering outsourcing the bending processing of sandwich panels, which is particularly labor-intensive. However, since Company A was in the process of promoting in-house production across the company, this consideration was put on hold. Therefore, our company proposed a design change for the relevant product. The proposed change in bending shape involved the design department and went through sample creation and strength verification before being commercialized. For mass production, a "panel bender" was introduced to start the process. The product using the targeted sandwich panels was able to reduce the number of bolts used from a total of 83 per product to 8. This results in a reduction of 75 bolts per product. Since this product is shipped at a rate of 22,000 units per year, this means a total annual reduction of 1.65 million bolts. [Case Overview] - Industry: Sheet metal processing - Product Shape: Panel shape - Plate Thickness: Mainly soft steel under 1.0mm - Production Volume: 100 units per lot - Concern: Low gross profit *For more details, please refer to the related link page or feel free to contact us.

Related Link - https://panelbender.salvagnini.co.jp/20201221-2/

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【Introduction Effects】 ■ For the targeted products using sandwich panels, the number of bolts used per product was reduced from a total of 83 to 8. ■ Since the work time for bolting is 3.5 seconds per unit, a total of 1,600 hours of work time was also saved annually. ■ Productivity has improved by approximately 2 times. ■ Part A, which previously processed 7 pieces per hour, can now process 15 pieces per hour, while Part B increased from 9 pieces to 16 pieces. ■ By making the bending line easier, workers were reassigned from the understaffed welding and painting lines, allowing for a more uniform processing speed across the entire factory and establishing a well-balanced production system. *For more details, please refer to the related link page or feel free to contact us.