Case Study: Tube Laser Redesign Cuts Cost And Lead Time
This case study illustrates how Dimar Manufacturing Corporation helped a customer save thousands of dollars annually by redesigning a high-volume tubular component.
By utilizing our new tube laser technology, the customer also cut lead time in half through faster, more efficient processing.
Introduction
Dimar Manufacturing Corporation continues to invest in cutting-edge capital equipment so customers can remain cost-efficient in an increasingly competitive market.
Leveraging New Tube Laser Technology
The installation of Dimar Manufacturing Corporation’s new BLM LT7 laser tube cutting machine has been a key contributor to identifying and executing cost-reduction opportunities without compromising product performance.
Background
The customer approached Dimar Manufacturing Corporation seeking cost reductions on a high-volume part used across multiple product lines.
Maintaining Performance While Reducing Cost
To remain competitive in their market, the customer asked for help designing cost out of the part while preserving its integrity, fit, form, and function.
Evaluation of the Original Design
An engineering review was conducted to understand where time, labor, and cost were being consumed in the existing manufacturing process.
Original Three-Piece Fabrication
Historically, the part was manufactured as three separate components.
Each piece was saw cut, holes were machined on a CNC mill, and the components were welded together using a dedicated weld fixture. This approach added multiple handling steps, machining time, and fixture-related labor.
Proposed Solution
Dimar Manufacturing Corporation evaluated how tube laser technology could simplify the process and reduce total manufacturing time.
Tube Laser Bend Cuts
Tube laser technology allows for more efficient fabrication through bend cuts and eliminates the need for secondary drilling operations.
This approach consolidated multiple operations into a single, streamlined cutting process using tube laser cutting.
Updated Frame Design
The redesigned frame incorporated “pie-shaped” cuts that allow the material to be formed by hand.
This design also enabled the part to self-fixture during welding, reducing the need for complex weld fixtures and additional setup time.
Results and Conclusion
Through a focused engineering review process, Dimar Manufacturing Corporation delivered measurable improvements in both cost and lead time.
Documented Time Savings
On an order of 100 frames, the updated process saved 18.75 total processing hours.
Switching from saw cutting and drilling to tube laser cutting saved 14 hours, directly reducing both cost and lead time. The self-fixtured weldment design saved nearly 5 additional hours of welding time.
Overall, this simple redesign saved the customer thousands of dollars annually while improving throughput and manufacturing efficiency.
Industry resources such as The Fabricator and Modern Machine Shop frequently highlight similar benefits when manufacturers adopt tube laser technology.
FAQ
The following questions summarize key takeaways from this tube laser case study.
What was the main goal of this project?
The goal was to reduce cost and lead time on a high-volume tubular part without affecting fit, form, or function.
How did the tube laser reduce processing time?
The tube laser eliminated secondary drilling and reduced cutting operations by consolidating them into a single process.
Why was welding time reduced?
The redesigned part used self-fixturing features, which minimized setup time and simplified the welding process.
Did the redesign affect product performance?
No. The redesign maintained the part’s integrity while improving manufacturability.
Can Dimar evaluate other tubular parts?
Yes. Dimar Manufacturing Corporation offers a free product analysis to identify similar cost-saving opportunities.
Watch the process in action here: Tube Laser Case Study Video.
Schedule your free product analysis with a Dimar Manufacturing Corporation representative today by visiting our contact page.