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simplify products with before &
after photos and details

Challenge:

• High product scrap rate

Achievement:

• Reduced scrap rate by 95%

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Challenges:

• Unit cost $300 over current target

Achievement:

• Total Annual Savings: $4,148,000

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Challenge:

• Execute a “no prototype” design – direct to production tooling schedule

Achievements:

• Reduced complexity of design allowed streamlined tooling
• Total Annual Savings: $5,170,000

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Challenge:

• Substantial weight reduction – theoretical target of 20 lbs/unit

Achievements:

• Reduced actual weight by 13.8 lb
• Tooling cost reduced by $750,000

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