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Challenges:

• Production capacity constrained by rework requirements
• Complex, difficult machining & assembly
• Poor in-plant Quality

Achievements:

• Market expansion due to increased production capacity
• Reduced machining & assembly complexity and improved quality
• Total Annual Savings: $2.4M
• Return on Investment of $2M in 9.8 months

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Challenges:

• Urgent market need – current technology not robust enough
• Delicate, complex, difficult assembly
• Frequent failures (leakage) in the field and very costly to correct

Achievements:

• Return on Investment of $400,000 in 6.3 months
• Field failures dramatically reduced
• Market expansion due to lower price and higher quality
• Reduced complexity of the product design and improved quality
• Reduced part count 62%
• Reduced number of operations 73%
• Reduced labor cost 70%
• Reduced material cost 63%
• Reduced Cost of Quality 65%
• Reduced total product cost 67%

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Challenges:

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

Achievements:

• Major cuts in part and labor costs while improving quality due to simplified design
• Total Annual Savings: $3,500,000
• Reduced complexity of the product design and improved Quality
• Reduced part count 38%
• Reduced number of operations 44%
• Reduced labor cost 46%
• Reduced material cost 32%
• Reduced Cost of Quality 16%
• Reduced total product cost 33%
• Return on Investment of $2.2M in 7.7 months

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Challenges:

• Frequent failures of delicate, complex valve in the field - very costly to correct
• Delicate, complex, difficult assembly
• Urgent market need - technology too expensive

Achievements:

• Simplified product design led to improved Quality and increased robustness
• Dramatic reduction in field failure rate drove significant Market expansion
• Reduced complexity of the product design and improved Quality
• Reduced part count 62%
• Reduced number of operations 73%
• Reduced labor cost 70%
• Reduced material cost 63%
• Reduced Cost of Quality 65%
• Reduced total product cost 67%
• Payback on $400,000 NRE in 6.3 months

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