Estes can help OEMs achieve cost savings through value engineering and its cost reduction processes.

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.

Engineer working on cost reduction process


Cost Reduction Through...

Salvagnini technology

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.

Cost reduction processes

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 through DFMA


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.

Let Estes reduce your manufacturing costs with our value engineering and cost reduction processes.

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.

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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.

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The redesign reduced the overall production cost to under $19 dollars and resulted in a 37% savings.



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Case Study #2 - Lean Manufacturing Provides Reduction in Costs

Client Need

After searching for a reliable rapid prototype vendor, one of the largest packing equipment suppliers in the world came across Estes Design and Manufacturing. This customer previously had issues with lead-time, reliability, and quality with other suppliers.

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Estes reduced the customer’s cost by 25% and the customer’s lead-time went from six weeks to ten days. By reducing the cost of the project through lean manufacturing, Estes could handle the production run allowing the customer the opportunity to bring its fabrication back to the United States from overseas.

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The prototype phase typically took months, but Estes was able to reduce this phase to a matter of days. The Estes team worked with the customer from concept and design to a finished, fabricated, fully painted, working prototype. During the design phase, Estes helped the customer modify its current designs for better manufacturability and quality.

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