Defense and Electronics Case Studies

Guidance Section – Honeywell, Sensor & Guidance Products

Challenges:

  • Complex & difficult manual assembly with multiple electrical connections
  • High component and assembly costs
  • Extreme operating environment

Achievements:

  • Major improvement in build quality
  • Design team earned Honeywell Excellence In Design Award
  • Reduced complexity of the product design and improved quality
  • Reduced part count 50%
  • Reduce number of operations 53%
  • Reduced assembly time 53%
  • Significant improvement in Total Product Costs

Hardened Computer

Challenges:

  • Poor in-plant Quality – very costly to correct
  • Complex, difficult assembly

Achievements:

  • Total Annual Savings: $990K
  • Reduced complexity of the product design and improved quality
  • Reduced Cost of Quality 85%
  • Reduced number of operations 94%
  • Reduced labor cost 96%
  • Reduced material cost 36%
  • Reduced total product cost 44%
  • Return on investment of $650K in 7.9 months

Transceiver

Challenges:

  • Poor in-plant Quality
  • Contract cancellation expected
  • Complex, difficult electronic assembly

Achievements:

  • Quality vastly improved; contract preserved
  • Total contract revenue retained: $449 million
    (Yes, that’s 449 million dollars)
  • Reduced complexity of the design and improved quality
  • Reduced number of operations 84%
  • Reduced labor cost 85%
  • Reduced material cost 66%
  • Reduced Cost of Quality 91%
  • Reduced total product cost 78%

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