Success Stories - Optimizer Consulting, LLC

01 / 03 — RAIL · FLEET ARCHITECTURE

A 3-truck rig,
collapsed into one.

Original deployment required three trucks. We took the architecture back to first principles and shipped a single welding truck with crew quarters — light enough to skip overweight permits.

→ Single truck and crew deployment vs. original 3-truck rig.
→ Patent-pending rail-storage system & integrated crane.
→ 12.5% weight savings eliminated overweight permits.
→ Project completed in 6 months, under budget.

−66%

Trucks deployed

−12.5%

Vehicle weight

6mo

Delivery

02 / 03 — POWERTRAIN · FRESH-EYES REVIEW

Engine review,
$1M a year out.

A Fresh-Eyes Review of an engine surfaced multiple opportunities. The biggest, fastest win: redesigning a billet manifold to a fully drop-in compliant permanent-mold tooled part.

→ Redesigned as a permanent-mold part — all casting features integrated.
→ Close feedback loop to first saleable samples.
→ FEA performed to validate the design before tooling kickoff.
→ Tolerance analysis improved bolt engagement, eliminated serrated fasteners.

$1M

Annual savings

1part

Drop-in compliant

FEA

Pre-tooling validated

03 / 03 — SUSPENSION · COMPONENT DESIGN

Knuckles, by the
geometry.

Fully parametric models driven by defined points from suspension software. Every casting feature — draft, parting line, fillets — lives in the model itself, not a separate drawing package.

Receipts.

A 3-truck rig, collapsed into one.

Engine review, $1M a year out.

Knuckles, by the geometry.

A 3-truck rig,
collapsed into one.

Engine review,
$1M a year out.

Knuckles, by the
geometry.