Intelligent Industrial Packaging Machinery Reduces Manufacturing Costs by 40%

A company with an ambitious vision of producing intelligent industrial packaging machinery faced multiple challenges due to their limited resources and expertise. To overcome these obstacles, they sought the assistance of PCN consultant, Scott Brannan, a highly experienced cost estimator with a proven track record of success in the industry. Scott's involvement in the project proved to be invaluable, as he was able to identify areas for improvement in both the design and manufacturing processes. Through his efforts, the company was able to achieve a remarkable 40% cost saving, ensuring the success of their project. This case study highlights the transformative power of hiring an expert with the right skills and experience.

The Problem:

A company had the ambitious vision of producing intelligent industrial packaging machinery - combining self-learning software with modular hardware. They faced multiple challenges - a small team of 6, most of them recent university graduates, a limited budget and limited mechanical knowledge.

The Solution:

They hired Scott who was recommended by an EV battery company in Norway as they had worked with him and knew he had the expertise to help. Scott provided the following support:

1. Cost estimation
2. Design review and redesign for manufacturability
3. Supplier selection
4. Achieving 40% cost savings

The Outcome:

Scott's extensive industry knowledge allowed him to identify areas of improvement across the project. Although initially only hired for cost estimation, he discovered that the product was too expensive in terms of design and suppliers.

1.  Scott conducted a thorough design review and made recommendations regarding wall thickness and design for manufacturability.
2. The client agreed to collaborate with Scott on redesigning the part, with all steps supported by estimates.
3. Over the next 12 months, Scott and the team worked together to reduce the total part weight from 478 grams to 285 grams. They also decreased the part count from 32 components to 22, implementing a clip-together design. Simplifications were made to ease manufacturing and lower costs.
4. As the client had no existing supplier network, they requested Scott's assistance in locating suppliers in the Baltic region.
5. Scott efficiently identified numerous suppliers for moulded parts, bearings, turned parts, PCBs, and motors.
6. Currently, all the plastic components have been sourced, resulting in a 40% cost saving compared to the original concept.
7. The client now collaborates with a capable supplier in Lithuania, benefiting from open communication and excellent support.

This case study exemplifies the transformative power of hiring an expert with extensive experience and a track record of successful projects. By leveraging external expertise, the client achieved a more efficient and cost-effective design, surpassing their original expectations. While possessing such talent in-house is challenging, the expertise provided by Scott made their idea a successful reality.

Scott Brannan

Scott is an experienced cost estimator who uses his vast industry knowledge to identify more efficient and cost-saving ways of manufacturing. Some examples of how he has saved companies millions in costs:

• €14 million savings at TRW by moving the steering rack ball nut from machined from solid part to a Hatebur hot forging and light machining.
• Uncovered £240.000 savings for an A380 duct by eliminating an X ray rework look within the process.
• He negotiated lifetime saving of £21M on EV HVAC valves for Dyson project.

PCN

Scott is just one of the highly experienced and qualified polymer consultants of the PCN. PCN is a global network of highly qualified plastics experts who can help you with anything you need, from product development to manufacturing to supply chain management.

Their experience of working with many different companies gives them an unmatched breadth and depth of knowledge in the plastics industry. Which means they understand very quickly what needs to be done and how it needs to be done, and can give you a good prediction of the results to expect.

When you work with PCN, you have the peace of mind knowing that you're getting the best possible advice and guidance from the industry's leading experts. And because they work on a flexible basis, you can get the help you need without committing to another salary on the payroll.

www.pcn.org