Success Stories - Cost Savings

eServ helps reduce cost of Spring Bracket

The Challenge

Cost reduce the current spring bracket without compromising the manufacturability or performance of the component.

Goals:

• Eliminate the current formed bracket in favor of a more simple design
• Use current scrap material to manufacture the new bracket
• Simplify the assembly process for line personnel

The Solution

eServ provided full spectrum engineering services including Design, Analysis, Testing, and Documentation in support of the bracket redesign. This activity included the following:

• Development of the Concept Design and required investigation into platform impact (cost, schedule, performance, etc.)
  
• Creation of test plans supporting the prototype, validation, and implementation phases of the project
  
• FE Analysis of the bracket and the structure verifying both component and system capability (complete stress and life cycle, including material creep, calculations)
  
• Supervision and evaluation of full system physical testing to insure proper function through a minimum of 40,000 cycles

The Results

The new bracket was put into full production with the following highlights:

• Accelerated production date to avoid a “Line Down” condition on the verbal approval of the responsible eServ engineer
  
• $56,000 annual cost savings with a total project investment of $10,715
  
• Universal assembly with quick reference feature for line personnel