Case Study: Streamlining LED Fixture Production Through Metal Stamping

At Talan Products, we recently partnered with a long-term customer to enhance the competitiveness of their LED light fixture chassis. This case study demonstrates how our expertise in metal stamping and Design for Manufacturability (DFM) led to significant improvements in production efficiency and cost savings.

Challenge

The customer’s LED light fixture chassis originally consisted of three separate metal stampings: a chassis body and two end caps. While functional, this design presented opportunities for improvement in component mounting and overall efficiency.

Solution

Our team, in collaboration with the customer and our tooling partner, developed an innovative solution:

• Integrated Design: We redesigned the chassis to incorporate the two end caps into the main body, creating a single-piece component.
• Progress Die Implementation: Utilizing a progress die in our stamping process, we were able to produce the entire chassis in one manufacturing cycle.

Results

The redesigned chassis yielded multiple benefits for our customer:

• Reduced Part Count: From three separate components to a single, integrated part.
• Improved Material Yield: Less waste, resulting in reduced material costs.
• Streamlined Inventory Management: Only one part number to track, reducing processing and storage requirements.
• Simplified Logistics: Fewer components led to reduced packaging and transportation costs.
• Efficient Assembly: Elimination of the assembly step for end caps significantly reduced labor time.
• Consistent Production Time: The new single-piece chassis required the same production time as one of the previous components.

Key Takeaways

• Early involvement in the design process allows for impactful DFM improvements.
• Integrating multiple parts into a single component can lead to substantial cost savings and efficiency gains.
• Collaboration between manufacturers, customers, and tooling partners is crucial for innovative solutions.

This case study exemplifies Talan Products’ commitment to leveraging our metal stamping expertise and DFM capabilities to create more competitive products for our customers. By getting involved early in the design process, we can help optimize your products for manufacturability and cost-effectiveness.

Contact Talan Products today to see how we can apply our expertise to your manufacturing challenges and help make your products more competitive in the market.

Posted in: Case Studies