Insights from Dark Red Design lead to a 30% reduction in engineering costs
Improved production techniques bring an upsurge in efficiency for leading Class 1 medical device manufacturer
Client’s Main Objective
A company producing developmental products for people with physical handicaps wanted to increase the durability and reduce the manufacturing costs of one of their most popular products.
The postural support was designed to help children and young adults with disabilities maintain a comfortable sitting position in a wide range of situations.
For many children with special needs, external support is needed to provide stability for the neck, head and pelvis while seated. Our client manufactured a range of devices to help with postural control that could be used in the home, at school or during therapy sessions.
One of their most effective and versatile products was deemed to be losing its competitive advantage in the market, and so Dark Red Design was engaged to update the design and streamline the manufacturing process.
The product’s entire development procedure was evaluated on site to establish where improvements could be made and what cost reduction measures could be applied.
Our integrated approach to the whole process meant we were able to factor manufacturability in from the start of the project, rather than as a final add-on, and so we assessed production methods along with the product’s design. We were able to identify several areas where savings could be made by introducing new techniques to redesign components, lowering the cost and number of parts and choosing better materials.
The benefits of the renewed design resulted in shorter engineering, processing and assembly times. The high volume production systems we put in place also led to a dramatic increase in build quality of the final product, with significantly reduced wastage. Overall, we were able to bring about a 30% drop in manufacturing costs for the client. One of the further added benefits of the updated support was a more robust design that weighed 10% less than its predecessor, making it much easier for users to lift and manoeuvre into place.