Success Stories - Cost Savings

Finger Guard & Baffle Redesign Strengthens Product & Achieves Cost Efficiencies

finger guard & baffle redesignThe Challenge

Cleaning out a wheel loader compactor can be a challenge for finger safety and efficient operation when debris clogs the passageway, causing overheating, stress on parts and even part failures due to vibration. Addressing these issues while achieving cost efficiencies became the goal for our client, the world’s largest manufacturer of construction and mining equipment. In manufacturing a medium wheel loader compactor for land fill usage, the fortune 100 company wanted to replace existing finger guards and baffles with a focus on achieving significant cost reductions.

Key issues were:

  • Resolving potential part failures due to vibration seen in testing the unit’s swing-out radiator
  • Avoid modification of any existing radiator components
  • Providing adequate room for the existing harnesses while maintaining proper protection

finger guard & baffle redesignThe Solution

eServ provided a cost-efficient and operationally efficient alternative to the assembly design that had resulted in weight stress fractures where the part bolted to the radiator. eServ’s engineering experts designed and provided detailed drawings of the finger guards and baffles. In addition, the engineering solutions team completed the design FMEA on the finger guards.

  • Concept Design
  • Cost Analysis
  • Project Management
  • FMEA Services
  • Production Drawings

The Results

eServ delivered the following results:

  • Cost savings of approximately 50 percent through concept redesign and improved manufacturing process. The new four – part baffle reduced excess scrap and costs. As part of the redesign, wire was used to increase airflow, also reducing costs by reducing weight stress implications.
  • Improved time-to-market with the redesign baffle, which provided ease of assembly. Modification of existing components was unnecessary due to the use of existing mounting locations. The one-piece inner finger guard was utilized without modification.
  • Improved design strength by eliminating vibration-induced stress. Mounting plates were extended and located within the same plane of the assembly. Also, weld studs were added to the baffles for locators and ease of assembly.
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