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

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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

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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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