New Architecture Rail Welding Truck and Product Strategy

Key improvements

  • Single truck and crew truck deployment vs original 3 truck deployment
  • Added patent pending rail storage system
  • Added Crane for rail manipulation
  • 12.5% Weight savings eliminated the need for overweight permits
  • Project completed in 6 months and under budget

Fresh Eyes Review of Engine, $1,000,000 Annual Cost Savings

A Fresh Eyes Review of an engine revealed multiple opportunities. The largest and quickest to implement was a redesign of a billet manifold to a fully drop in compliant permanent mold tooled part.

  • Redesigned part as a permanent mold part. All casting features integrated into the model.
  • Close feedback loop to get saleable first samples
  • FEA performed to validate design before tooling kickoff
  • Tolerance analysis to improve bolt engagement and eliminate serrated fasteners

Suspension Knuckle Designs

Component Design of Suspension Components

  • Fully parametric models driven by defined points from suspension software.
  • All casting information in model. Full draft, parting line, and fillets