Case Studies

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Special Fluorescent Socket

Challenge:

One of our customers for our fluorescent products had a situation where their supplier of a special type fluorescent lamp holder went out of business. Consequently, they could no longer get these parts. Driven by their customer’s demand for service parts, they came to us for help.

Our Solution:

Working closely with our customer, we re-created all the molds, stamping dies, and assembly fixtures necessary to produce this special lamp holder. The results were that our customer was not only able to supply replacement parts, but able to re-activate the fluorescent fixture that had been discontinued and now they have new sales opportunities for this lighting fixture.

Scope of Work:

  • Designed and built new molds and stamping dies to produce the various components.
  • Worked from an example part as no original drawings were available.
  • Utilized our assembly knowledge to create fixtures to make assembly easy and efficient.

 

Electronic Temperature Control Component

case studiesChallenge:

A major producer of laundry equipment needed a subassembly component for their electronic temperature control which needed to be built to high standards with multiple tests performed throughout the manufacturing process.

Our Solution:

Using the customer’s specifications and test parameters, we built the necessary insert molds. Then we designed and built the test equipment and fixtures that were an integral part of the production assembly line. The assemblies were then put through the multiple tests at each stage of production ensuring the robustness and integrity of every single part. Using our experience, we created an efficient and cost effective production line to create this assembly that exceeded production volume and quality expectations.

Scope of Work:

  • Utilized our in-house mold making and design capabilities
  • Designed and built custom configured test equipment
  • Streamlined assembly with efficient use of custom built fixtures and assembly aids
  • Maintained consistent on-time delivery with quick reaction to fluctuating schedules.

 

Special Mounting of a Standard Device

Challenge:

A customer wanted to use our snap-in convenience outlet and male load plug on their product. The challenge was that it was to mount into a plastic housing that was a little too soft to provide good retention of the device. They were concerned that the outlets and plugs would come out of their unit without much effort.

Our Solution:

We suggested a modification to the inside of their housing which would allow our modified mounting clip to have a solid and stable “capture” of the outlet and load plug. This resulted in a robust mounting feature that while it would not come loose, it still could be removed if it ever needed service or replacement.

Scope of Work:

  • Creative in-house engineered solutions
  • Rapid tool changes
  • Efficient and timely customization to fit customer’s needs

 

Soldered Assembly and Special Metal Stamping

Challenge:

A new customer came to us with a new product they were developing. They were looking for a manufacturer with experience in soldered assemblies.

Our Solution:

We were able to work together with them in the development of a soldered diode assembly that was to be used in their product. Additionally we provided several different cut pieces of material for them to use in their assembly along with the diode assembly. As the project developed, we were tasked with providing a special metal stamping that by its nature is rather delicate. We also designed the special packaging required for the diode assembly and the metal stamping to insure that the product could be delivered undamaged and intact.

Scope of Work:

  • Used our soldering expertise to select the proper equipment, design and build the assembly fixtures necessary, and employ the most efficient methods of soldering and testing the assembly.
  • Utilized our stamping die designing and building experience to create the tools to make the special stamping from the soft and rather delicate material and developed methods to efficiently handle these parts.
  • Developed and refined special packaging to protect the product from the rigors of shipping that resulted in robust , simple, and cost effective product packaging.