Success Stories - Cost Savings

eServ helps Fortune 500 Manufacturer with Cost-Saving Solutions

The Challenge

eServ’s Analysis Team couples experience and knowledge with world-class dimensional analysis software to provide our client -- a Fortune 500 manufacturer -- cost-saving manufacturing solutions.

• Supplier redesign prior to production
  
• Theoretical’ in-line inspection for acceptable tolerance
  
• Cost effective design change

Fuel Pump Redesign
Original design required fuel pump to be adjusted on the assembly line to ensure proper timing, and it was desired to take this adjustment out.

Timing Sensor Analysis
It was desired to have in-line inspection of an engine to determine if the timing of the engine was within an acceptable angular range.

Fuel Injector Leakage Analysis
Several fuel leakage problems prompted eServ’s client to evaluate the assembly to determine if the problem was caused by a design flaw.

The Solution

Fuel Pump Redesign
Tolerance analysis studies were conducted to identify and prioritize misalignment problems caused by supplier’s design.

Analysis Findings: A VSA analysis was performed on the design proposed by the fuel pump supplier. It was determined that there was an excessive amount of variability internal to the fuel pump itself.

Fuel Injector Leakage Analysis
Tolerance measurements were analyzed to discover the cause of fuel leaking around the fuel line’s o-ring.

Analysis Findings: It was determined by way of VSA simulation that the existing design could have the potential for a certain percentage of injectors to leaks.

Timing Sensor Analysis
Four statistical analyses were completed to reassure manufacturing that the assembly was accurate.

Analysis Findings: VSA analysis results showed that, based off of the dimensional tolerances the parts were being manufactured to, the variation would fall inside the acceptable design limits.

The Results

eServ dimensional analysis heads off production-line downtime -- saves cost, improves time to market.

Fuel Pump Redesign
Outcome / Results: eServ’s client was able to take this information to the supplier and, backed with solid documentation, require them to redesign the pump to ensure a more accurate and repeatable assembly method. All of this was done prior to any pumps actually being produced.

Timing Sensor Analysis
Outcome / Results: eServ’s client was able to start production without the inspection equipment with the confidence that, assuming the parts were all manufactured to spec, the engine would be built with the proper timing.

Fuel Injector Leakage Analysis
Outcome / Results: Multiple iterations were run using a range of alternative solutions to determine the most cost effective way to resolve the problem. In the end, an inexpensive resolution was incorporated that virtually eliminated the potential for leakage under normal circumstances.