Optimizing 3D Sheet Metal Designs for a Large German Plant
- 800+ parts optimized in 3 months
- 10% Increase in production efficiency
Background
Our client, a large manufacturing plant based in Germany, sought to optimize the designs of their sheet metal structures. The company was facing challenges with the manufacturing efficiency of several parts, which required redesigning and reverse-engineering the 3D input files to align with stringent Design for Manufacturing (DFM) standards. The aim was to ensure smoother production processes and eliminate issues that could hinder manufacturing quality, timeline, and cost.
Challenge
The client’s existing designs for sheet metal parts were prone to inefficiencies when transitioned into production, resulting in delays and increased costs. The primary challenge was to bring these parts in line with industry-leading DFM standards while maintaining functionality. With 800+ parts to be reworked, the task involved ensuring every piece met precise specifications while optimizing the designs for production scalability. Additionally, the complexity of working with large-scale assemblies and detailed drawings—ranging from General Arrangement (GA) to part-level drawings—added to the challenge of maintaining design integrity and reducing errors during manufacturing.
Solution
To address these challenges, our team of experts at Srushty Global Solutions employed an in-depth reverse engineering process for the 3D input files. We started by analyzing the designs thoroughly, identifying areas where DFM optimizations could be made, such as material reduction, part simplification, improved assembly efficiency, and cost reduction. Over the past three months, we successfully updated the DFM requirements for 800+ parts, ensuring they were optimized for manufacturability.
Our solution included:
2D Drafting & 3D Modeling: We converted the existing 3D models into updated 2D drafts and reworked the 3D models to reflect the new design requirements.
General Arrangement (GA) Drawing: We delivered precise GA drawings to provide a clear visual representation of the overall assembly, helping engineers understand the placement and integration of each part.
Assembly & Weldment Drawings: We provided comprehensive assembly and weldment drawings that ensured a clear understanding of how each part fits within the larger structure, guiding the assembly process and ensuring minimal errors.
Part Drawings: Detailed part-level drawings were created for manufacturing teams to ensure accurate cutting, bending, and welding of each individual sheet metal component.
Impact
The optimization of 800+ parts has had a significant positive impact on the client’s operations:
Improved Manufacturing Efficiency: The updated DFM designs streamlined the production process, reducing assembly time and minimizing the risk of errors.
Cost Reduction: By optimizing part designs for manufacturability and material usage, the client experienced substantial cost savings, leading to an overall reduction in manufacturing expenses.
Enhanced Quality Control: The precision in the updated 2D and 3D drawings helped avoid misalignments and mistakes during production, ensuring higher product quality and reduced rework.
Faster Turnaround Time: With the optimized designs, production timelines were shortened, enabling faster delivery to meet tight deadlines set by the German plant.
Scalability: The design updates allowed for smoother scaling of production to meet future demand with minimal adjustments.
By leveraging reverse engineering and DFM optimization techniques, we successfully improved the manufacturability of over 800 sheet metal parts for our client, delivering updated 2D and 3D drawings that met the high standards required for large-scale production. This project not only saved the client significant costs but also ensured smoother, error-free production processes—ultimately contributing to their operational efficiency and market competitiveness.
