Cost Reduction Though Improvements To Manufacturability
Following a Value Analysis and Value Engineering (VAVE) exercise, we identified a cost-savings opportunity by changing the pack cooler in a multiplex testing system. The change improved manufacturability by reducing the labor time and requirement for specialized skills. Additionally, the design change improved lead time for manufacturing and reduced product risks through replacement of aging specialty tooling.
55%
Savings per Unit
Supported by Comprehensive Testing
Extensive fit, form, and function testing was performed on multiple validation prototypes. Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) tools were used to assess and address risks to performance, reliability, and manufacturability.
Design Changes
Spun Aluminum Bowl
Updated design replaced the stainless steel double-walled, welded bowl with a simpler spun aluminim bowl. The reduction in required welds also reduced the risk of warranty issues caused by leaks.
Copper Tube Cooling Pipe
Welded cooling pipes replaced with copper tube that is formed and attached to the bowl along with a polyurethane overmold. This new overmold design also eliminated cracking issues caused by hoop stress in the prior design.
