In addition to receiving a better product in a shorter lead time, most OEMs want a product produced at a reduced cost.

Estes can assist OEMs in achieving just that. Using a process known as value engineering, Estes’ team (which includes eight engineers with over 150 years of combined engineering experience) evaluates a customer’s part looking for ways to reduce manufacturing costs and to simplify assembly (DFMA). Value engineering delivers parts at a lower cost that are easier to assemble.

Visit Estes’ case studies to see how the company has helped OEMs achieve cost savings through its cost reduction process.

Employees working together on cost reduction process

Let Estes reduce your manufacturing costs with value engineering.

Case Studies

Case Study #1

Panel bender redesign provides cost savings

Client Need

The original design of a client’s steel pan used in a medical application was a three-piece, spot welded assembly that cost $29.65.

Estes Solution

To increase manufacturing efficiency, the Estes team utilized the Salvagnini forming cell. The three components were consolidated into one complex, yet more economic part with twelve bends. The redesign reduced the overall production cost to under $19 dollars and resulted in a 37% savings.

Case Study #2

Cost reduction benefits of 3D laser welding

Client Need

The design for a client’s stainless steel box consisted of four pieces formed in a Z-shape at the press brake. These four pieces were then welded at the corners, which caused the stainless steel to warp slightly. The assembly had a brushed, cosmetic flange around the perimeter that would remain visible to the end user. To maintain an appealing look, the welds had to be ground, and then the flange had to be brushed.

Estes Solution

This finishing process was very labor-intensive and costly, so Estes proposed a redesign to the customer. Utilizing their Salvagnini forming cell’s capability to form complex, tight-tolerance bends, they formed the part from one blank instead of four. The edges were brought together so precisely they could be laser welded at the seams. The laser welding eliminated the warping and the secondary finishing.

The reduction of components and of finishing and assembly time dropped the cost of production from $43.73 to $38.73, while improving the quality of the part.