A question for the ages. There are really a lot of reasons to redesign like modernizing the product, adding features, etcetera. But there are couple not so obvious reason I want to talk about here.
Many times as a product is developed, initial volumes are low and the focus is getting a working product to market. The methods and materials used to produce it are based on low volume and are geared to keep the initial startup costs low. After all, if it is truly new, how can you be sure if it will actually sell? And, it’s not unusual for a company to just keep producing it that way if it is successful.
So the first reason would be part cost reduction.
Case in point. I worked for a company a number of years ago that had developed a product that used two aluminum parts. They were machined from 1’ thick aluminum material into two half circle parts and each one had 6 holes machined into them. One set cost $40.00. even after the product had become successful they just kept making them the same way for years. Eventually we redesigned the product and were able to create the half circle shape as an aluminum extrusion with the holes included in the profile. The extrusion was then sliced into 1” lengths to give us the finished shape. The new part did not have to be solid so we were able to substantially lower the weight and cost. The cost of a set with the new design was only $5.00. We actually wound up with a better product and a huge savings.
The second reason I want to discuss here is to reduce assembly cost.
Case in point. We were manufacturing a stand from an aluminum
extrusion. The feet for the stand where also fabricated from the same extrusion. Holes were drilled for mounting them to the uprights, for mounting the wheels and for attaching the cross-bracing. End caps were cut from aluminum strapping, drilled and fastened to each end of the extrusion feet. It took 30 minutes per stand to fabricate the feet. By redesigning the feet as a plastic injection molded part the need for the bracing was eliminated, the wheels were just snapped in and two self-taping screws held each [foot] to the uprights. The total assembly time for the feet was reduced to 3 minutes. Besides the obvious labor savings this had a huge impact on the backlog in the department that made them. So we had a better looking and higher quality solution that improved customer service and reduced cost.
If you have a part or product that is difficult or time consuming to produce, why not give DREaM a call and put our 30+ years of experience to work for you.
Design Smart, Design Right!