Challenges:

• Tight electronics packaging with multiple PCB’s in a small, complex unit
• High cost in material & labor
• Difficult housing assembly with many small parts

Achievements:

• Integrated and simplified PCB assemblies & enclosure
• Reduced part count 80%
• Reduce number of operations 75%
• Reduced labor cost 78%
• Reduced total product cost significantly
• Improved functionality, integrated additional features, improved quality

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Challenges:

• Complex system with carry over design
• Difficult to assemble and install
• Ergo and Quality issues

Achievements:

• Total annual savings: $520K
• Reduced complexity of the product design and improved quality
• Reduced total product cost 42%
• Reduced number of operations 41%
• Reduced number of parts by 43%
• Reduced number of fasteners by 37%
• Reduced labor cost 30%
• Reduced material cost 44%
• Reduced Cost of Quality 47%

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