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.

Engineer working on cost reduction process

Cost Reduction Through...

cost reduction processes

Automated Technology

In the late 1990s, we shifted our focus at Estes Design and Manufacturing to technology and automation in an effort to differentiate ourselves from our competitors. Since then, we’ve tried to continuously improve our equipment to stay on the leading edge and bring the benefits of the latest technology to bear on our customers’ products.

In the world of sheet metal fabrication, speed and quality mean everything to our customers, and high levels of automation maximize uptime and improve part accuracy and consistency while lowering costs. To learn more about our state-of-the-art equipment take a virtual tour.

Lean Initiatives

We continuously strive to reduce lead-times, improve quality, and reduce costs, and our long-term business model is geared toward these lean initiatives.

As an example of our lean initiatives, our team focuses on waste versus value-added activities in the manufacturing process, which means our employees are identifying and removing wasteful practices from their production and constantly seeking improvement. At Estes, we believe the best way to improve is to constantly re-evaluate and grow as an employee—which makes for a stronger company.

Cost reduction processes
Cost reduction processes through DFMA

Design for Manufacturing & Assembly

Design for manufacturing and assembly (DFMA) can add value to your product by increasing speed to market, improving production efficiency, and lowering the cost per part.

DFMA works to find solutions for potential manufacturing and assembly impediments that could disrupt your manufacturing processes, timelines, and budget. It works to align engineering and production during the design phase, going beyond fit and function.

Estes engineers draw on their manufacturing expertise to translate ideas from concept to manufacturing while applying DFMA principles throughout the development process.

Read more

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.