Reinventing an Exhaust Clamp: A Collaboration That Delivered Strength and Savings
Introduction
The Engineering and Procurement departments at a Heavy Equipment manufacturer were facing challenges with one of their Exhaust Aftertreatment products. The company required a more cost-effective and structurally improved large exhaust system mounting clamp to enhance durability and reduce overall expenses.
Challenges
The manufacturer was using a standard product from an exclusive supplier, limiting their supply base options, and resulting in high cost for the existing clamp. Additionally, the product suffered from failures during assembly (breaking under tightening force) and fatigue failures in the field due to structural weaknesses. They needed an alternative design that would both reduce costs and improve reliability.
Solution
The manufacturer collaborated with KMC, which designed a stronger and lower-cost exhaust system mounting clamp. The KMC solution incorporated:
- Shared punch press tooling and optimized weld fixtures, reducing manufacturing costs and enabling flexibility for additional sizes.
- Heavier gauge material for greater strength and resistance to fatigue failures.
- An improved welding process that enhanced durability.
- Alternative fastening methods that prevented breakage during assembly.
KMC’s design provided cost savings, superior strength, and scalability.
Conclusion
By implementing KMC’s solution, the manufacturer achieved significant cost savings:
- Per-unit cost reduction from $28 to $22.25 for 18,000 units annually.
- Over $200,000 in annual savings after adding a second part.
- Lower failure rates in both assembly and field applications.
KMC’s investment in Capital Equipment helped streamline production, ensuring long-term cost efficiency and scalability for the manufacturer’s exhaust system. This collaboration provided a more cost-effective, robust, and flexible solution, reinforcing the manufacturer’s commitment to innovation and quality in the heavy equipment industry.
