Customer Overview
The client is a leading manufacturer of garbage disposal trucks, producing multiple variants for global markets. As product complexity increased, the company needed to redesign its fabrication and assembly tooling to support multiple variants efficiently, while maintaining high quality and operator safety.
Highlights
Modular fixtures for multiple component variants
Turn-over mechanisms for dual-side usage and space savings
Pneumatic/hydraulic actuation for precise operations
Movable gantries for large-to-small component welding
Collapsible structures for enhanced operator reach
Fixtures manufactured in India for global shipping
Error-proofing (Poka-Yoke) for quality consistency
Bussiness Challenges
The client faced several manufacturing and operational constraints:
Existing fixtures were variant-specific, leading to high tooling costs and limited flexibility.
Large components with complex geometries made operator access and reachability difficult during assembly and welding.
Floor space utilization was sub-optimal, with single-purpose fixtures occupying significant production area.
The cost of manufacturing fixtures overseas was high, impacting overall project economics.
Key Features
Modular, scalable fixture design
Space-optimized layouts with turn-over mechanisms
Ergonomic, operator-friendly collapsible fixtures
Integrated actuation systems for ease of use
Cost-effective offshore manufacturing and logistics
Quality and safety built into every design
USMICRO Solution
1. Modular Fixture Design
a. Designed fixtures to handle multiple component variants within the same base, minimizing the need for separate tooling.
2. Advanced Actuation Systems
a. Integrated pneumatic or hydraulic cylinders for actuation of structures, clamps, and locators, improving precision and ease of use.
3. Turn-Over & Space Optimization Mechanisms
a. Employed turn-over mechanisms to utilize both sides of the fixture base, saving floor space and increasing productivity.
4. Flexible Gantry Systems
a. Added movable gantry mechanisms for welding multiple small components onto large assemblies efficiently.
5. Collapsible & Accessible Fixtures
a. Designed collapsible fixtures to enhance operator access to large and complex geometries, improving ergonomics and safety.
6. Poka-Yoke Integration
a. Incorporated error-proofing techniques to minimize assembly errors and ensure consistent quality.
Business Impact
The re-engineered tooling delivered tangible operational and financial benefits:
| Impact Area | Before | After (Post USMICRO Transformation) | Improvement |
|---|---|---|---|
| Tooling Cost | Separate fixtures for each variant | Modular fixtures for multiple variants | Significant cost reduction |
| Floor Space Utilization | Single-side fixtures, high footprint | Turn-over & collapsible mechanisms reduced footprint | Optimized space usage |
| Operator Accessibility | Restricted reach for large parts | Collapsible & ergonomic fixtures improved access | Safer, more efficient |
| Manufacturing Cost | Overseas fixture manufacturing | Fixtures manufactured in India and shipped overseas | Lower manufacturing cost |
| Production Flexibility | Rigid, variant-specific tooling | Modular design supported multiple configurations | Increased flexibility |
Bussiness Values
- Cost Optimization – Modular design and Indian manufacturing significantly lowered tooling costs.
- Operational Efficiency – Space-saving mechanisms and better ergonomics improved production throughput.
- Flexibility – Single fixtures now handle multiple variants, reducing lead times and increasing adaptability.
- Quality Assurance – Poka-Yoke and advanced actuation improved assembly accuracy and reduced rework.
