Aerial Equipment – Universal Reservoir

Challenge

A leading producer of mobile aerial equipment work platforms, including boom and scissor lifts, needed to reduce its direct material costs of hydraulic reservoirs while improving delivery flexibility and lead-time.

Solution

Utilizing the Helical Program, ÆÞÓÑapp helped the customer realize a 19% savings by employing the following techniques:

• 30% reduction in purchase part components, through applying part standardization techniques within the demand matrix tool-set.
• 40% reduction in workcenters by implementing the product process simplification tool-set.
• 68% increase in manufacturing throughput by applying R4 production streets.
• 60% reduction in workcenter set-up by standardizing material types.

Printable Case Study (PDF)

Universal Reservoir – Refuse Equipment

Challenge

• Oil leaking from filter assembly
• Need for one universal reservoir for all models

Solution

• Integrate filter assembly into a reservoir to eliminate leak points.
• Utilize ÆÞÓÑapp design toolsets to optimize available working envelope, resulting in a common fluid conditioning system across multiple truck models.

CLIENT — Bridgeport Manufacturing
Printable Case Study (PDF)

Reducing Total Operating Costs On Mining Equipment

Challenge

A leading manufacturer of construction and mining equipment needed to reduce annual costs to remain competitive in its markets.

Solution

Utilizing the Helical Program, ÆÞÓÑapp helped the customer realize a 26% savings by employing the following techniques:

• 25% reduction in purchase finished components leveraging the Demand Matrix tool-set.
• 85% reduction in workcenter set-up by applying quick-change weld fixtures while providing higher variation in daily build schedules.
• 60% increase in manufacturing throughput by applying R4 production streets.

Printable Case Study (PDF)

Simplified Hydraulic Tank Redesign For Construction Equipment

Challenge

A leading manufacturer of telescopic loading construction equipment requested redesign ideas to simplify the hydraulic tank and circuit to alleviate existing filtration problems, lengthy assembly time and vendor complexity.

Solution

Utilizing the Helical Program, ÆÞÓÑapp redesigned the hydraulic sub-system to ensure proper filtration, gauge pressure and overall functionality. The following quantitative benefits were realized:

• Reduce Bill of Material size by 20%
• Reduce Material Combinations by 75%
• Reduce Press Brake Set-ups by 75%
• Reduce The Number of Vendors by 93%
• Overall Cost Reduction by 11%

EQUIPMENT: Telescopic Fork Boom
Printable Case Study (PDF)

HydroNucleation Technology For Lift Equipment

Challenge

• Based on availability, customer was intending on using a reservoir much larger than hydraulic system requirements.

Solution

• Utilizing HydroNucleation technology to commonize two platform requirements into one common fluid conditioning device.

CLIENT — Elliott Equipment Company
Printable Case Study (PDF)

HydroNucleation Technology For JLG Industries

Challenge

• To provide a cost reduced common hydraulic tank for the JLG Series 800A and 800S Series boom lifts.

Solution

• Design a common tank for two specific models to reduce total cost.
• Improve internal tank design to enhance filtration, reduce assembly time and leak points
• Improvements also gain a larger share of the aftermarkets parts

CLIENT — JLG Industries
Printable Case Study (PDF)

HydroNucleation Technology For Firefighting Equipment

Challenge

• To develop a hydraulic reservoir solution that reduces weight, cost and line assembly time for their Tier IV Airport Rescue Vehicle line
• Meet the additional requirement for eco-friendly filter changes

Solution

• Utilize HydroNucleation technology to reduce weight by 15%, installed cost by 32% and shorten assembly line time by 25 minutes
• Provide a self-contained hydraulic filter element for eco-friendly replacement.

CLIENT — Oshkosh Corporation
Printable Case Study (PDF)

Combination Fuel and Hydraulic Reservoir

Challenge

A large OEM of telescopic material handling equipment had experienced severe quality defects on its combination fuel/hydraulic reservoir causing assembly line downtime and field warranty failures.

Solution

Utilizing the Helical Program, ÆÞÓÑapp helped the customer realize a cost savings of 9% while producing a defect-free assembly utilizing the following techniques:

• Reduced potential failure modes by redesigning the reservoir. Modified part fit-up, bend radii, material types and drain locations to create a defect-free assembly.
• 50% reduction in reservoir leak point weld seams.
• 7x increase in manufacturing throughput by applying R4 production streets.
• In-house paint capabilities enabled better appearance control for a highly cosmetic assembly.

Printable Case Study (PDF)