Manufacturing issues

    A medical device manufacturer had been producing a very delicate medical surgical part in low volume and was ready to commit to a high speed / high volume manufacturing process. Our engineering team worked closely with the customer to identify the program requirements, critical dimensions and the challenges within the customer’s subsequent assembly process. 

    Redesign Process

    Our tooling department designed and built, prototype parts to prove the design concept and to analyze how the material would behave in production. Later, a progressive die was designed and built in-house using the knowledge we gained through the prototyping process. This methodology can save time by uncovering hidden challenges before they reveal themselves in a production environment. 


    This stainless steel part that started with short stamping tooling is now running on progressive tooling with the capability of producing 45 parts per minute. The progressive tooling has a life of 750 thousand parts and is guaranteed for the life of the program. In this case the customer’s component cost was reduced dramatically from $2.3 per unit to $0.92 per unit.

  • Redesign Process 

    First, Andea conducted a form analysis to ensure the formability of the frame would continue to meet performance requirements as a one-piece design.  This trial and error process tested various grades of aluminum in the stamping press. 
    Second, Andea utilized our fiber laser to cut different strip configurations during the testing process which allowed us to fine tune the die design to eliminate wrinkles.   Our designers utilized their technical expertise during prototyping to design out potential issues in the progressive die.


    Manufacturing issues

    Increasing costs and maintaining consistent accuracy were the major issues developing in Rockwell’s two-piece welded stainless steel assembly frame with inserted hardware.

    Manufacturing issues

    Produce the frame without assembly and improve overall quality and accuracy of the frame.


    In this case the customer’s component cost was reduced dramatically from $7.2 per unit to $4.42 per unit.

Case Study