DFM Optimization for High-Volume Sheet Metal Electronics Enclosures
Summary
ElectroCase Manufacturing struggled with complex sheet metal designs requiring extensive secondary operations. Their telecommunications equipment enclosures had 23 separate forming operations and costly welding requirements.
The Challenge
Initial Need:
ElectroCase Manufacturing required DFM optimization for telecommunications equipment enclosures involving 23 separate forming operations, extensive welding, and secondary finishing processes that created bottlenecks in high-volume production.
Pain Points:
Complex forming sequence requiring multiple press operations
Extensive welding operations affecting dimensional stability
Secondary finishing processes adding 3-4 days per unit
Material waste exceeding 35% due to complex nesting requirements
Our Solution
Our Approach:
Integrated design approach using progressive die stamping for single-operation forming, tab-and-slot assembly to eliminate welding, optimized bend radii for material flow, and integrated mounting features to reduce secondary operations.
Methodology:
Finite element analysis using ANSYS for stress distribution, progressive die design optimization, material nesting analysis, and prototype validation with comprehensive dimensional inspection and assembly fit verification.
Final Summary:
Final design reduced operations from 23 to 3 steps, eliminated welding entirely, achieved 92% material utilization, and enabled single-shift production of 500 units daily with improved dimensional consistency and surface quality.
Execution
Process Description:
Manufacturing implementation involved progressive die tooling with automated material handling, servo-driven press controls, integrated quality monitoring, and powder coating line optimization for improved throughput and finish quality.
Outcome
Value Comparison:
Production operations reduced by 87%, material waste reduced to 8%, cycle time reduced from 4.5 days to 6 hours, and quality improvements resulted in 99.2% first-pass yield with 60% reduction in manufacturing costs.
Client Testimonial:
"The DFM optimization transformed our sheet metal operations from a complex multi-step process to an efficient single-operation production line while improving quality."
- Production Manager, ElectroCase Manufacturing