Reducing complexities

Reducing complexities


Client approached us with a request to simplify the design for upper track reinforcements. The original design called for a 3-piece assembly with a total of 6 individual stampings (Upper RT and LT, Lower RT and LT, End Reinforcement RT and LT) process required 2 separate weld cells with 14 welds per hand and a total of 16 operators.


Our approach simplified the process by changing this 3-piece assembly into a single piece stamping. This eliminated the assembly process and reduced the total number of operators needed to 6.


  • Reduced manpower by 10
  • Eliminated weld assembly line and adhesive sealing operation
  • Improved dimensional quality
  • Reduced weight by 1 lb. per vehicle
  • Cost savings of $3.5 million

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49495 Gratiot Avenue
Chesterfield, Michigan 48051
Phone: 586-949-6000
Fax: 586-949-1651
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