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Previously both these 2 items were cut with saws, then drilled or punched before being welded together. By cutting the parts on a rotary laser, the manufacturing time decreased and assembly was quicker since the individual pieces are made to finer tolerances. |
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This orange box was previously made from
plain steel which we spot- welded together then painted. Now we
manufacture the box from pre-painted steel and clinch the pieces
together instead of spot welding. Specifications
are maintained and the customer cut
his cost by around 10%. In a classic
example of lean manufacturing, eliminating
painting lowered our cost, decreased turnaround time, and made smaller
batches cost effective. |
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This part was previously assembled using
a jig to hold 3 pieces in place during welding. Now a rotary
laser cuts the tubing with notches, which
match with notches in the 2 plates. The parts are now “self-jigging”.
They mate with less labor and higher
precision. |
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Our customer desired to lower
his cost by eliminating standoffs and
other hardware previously required in his electronic chassis. We
redesigned the chassis so
the circuit board could simply be sandwiched between the top and
bottom sections of the box without screws, as shown in these three pictures. |
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Circuit board is
sandwiched and held firmly in place without screws, between the
two bent edges. |
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Using today’s brakes and off-line
programming, it is possible to replace
joints, welds and even fasteners with bends. Above
is what looks like
2 boxes sitting side by side. In reality,
both boxes are made of a single piece of steel. Tabs
are designed and laser-cut into the various
sides to lock the corners together without
any welding or other fasteners. The
part was designed in SolidWorks software and the brake
was programmed offline. All 23 bends
are made in one setup, reducing manufacturing
time to a minimum. |
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Above are examples of products re-designed for customers
using Arrow Sheet Metal’s Design/Assist
service to lower costs.