Case Studies and Real World Examples of cost reductions and manufacturing improvements realized from Dalsin technical staff review:
Sunpower - Global Fabrication Supply Chain
In 2004, Power Light, a major producer of solar rooftop mounting solutions, selected Dalsin Industries as a primary supplier. Power Light's criteria for a centralized production location and easy access to U.S. east- and west-coast destinations were initial screening criteria. Dalsin earned Power Light's business because it found a way to accept all of Power Light's business because it found a way to accept all of Power Light's designs using existing capabilities and technology and cost-effective production approaches.
3D Printing with FDM Technology
Dalsin Industries has a long history of investing in new production technologies to expand our ability to serve our customers’ needs. We have expanded into 3D thermoplastic printing using FDM (Fused Deposition Modeling™) technology. 3D printing is an additive manufacturing process which creates three dimensional solid objects from a digital CAD file. This is accomplished without special tooling and can create products with highly complex geometries
Dalsin Industries is a value-driven precision metal product manufacturer known for its innovative, efficient, and cost-effective manufacturing solutions. We partner with our OEM clients, working with them supplying design support through delivery of the final product, manufacturing high quality, sheet metal fabricated and stamped products.
Cost Reduction through Redesign
Starting with the original design for a door panel assembly requiring 5 pieces to be spot welded, Dalsin Industries reduced the part to 1 piece with no spot welds using automated cnc panel bending technology. This innovative redesign reduced the cost significantly, cycle time by 60% and the steel content by 17%.
9 -Piece part is Reduced to 1 piece
After examining the customer's sheet metal assembly we saw an opportunity to significantly reduce the number of parts and operations needed to produce the same assembly through our processes. This 9-piece assembly was reduced to 1 piece. We eliminated 18 spot welds, shortened the manufacturing cycle time by 57% through elimination of 11 process operations and reduced the steel content by 4%.
Redesign for Pre-painted Processing
In order to take advantage of the lower cost of pre-painted material our engineering staff redesigned this under counter cabinet assembly to successfully manufacture from non-PVC-coated pre-painted material. This change resulted in a 22% cost reduction and shortened the manufacturing cycle time by 30%.
Fastener Reduction Improves Cycle Times
The redesign of this drawer assembly using state of the art Salvagnin P4 automated panel bending technology eliminated 4 parts, 18 spot welds and 32 threaded fasteners per drawer. The drawer pull mechanism was replaced with a more ergonomic design. There was a 22% reduction in overall cost and the manufacturing cycle time decreased by 18%.
Increased weld productivity through redesign
This 3-piece assembly was reduced to 1 piece using cnc panel bending technology. 18 inches of weld was eliminated along with 2 operations. Increased weld productivity was achieved through reduction of part handling and fixture requirements with self-fixturing features. No tooling was required after the redesign. The manufacturing cycle time was reduced significantly.
Elimination of Corner Welds
Welding and then grinding corner welds on sheet metal assemblies can cost as much as the forming on all sheet metal parts that go into final assembly. Using our panel bending technology to form tight tolerance tight corner conditions not only eliminates the need for welding and grinding (eliminating significant cost), but it also creates a more consistent part quality and aesthetically pleasing assembly.