Other Industries Case Study

Part Consolidation / Fuel Industry

Background

A manufacturer in the fuel servicing industry builds hose reels for fuel trucks which function to allow the hose to be pulled from the truck to the customer’s home. When fueling is complete, the hose ratchets back to the truck. The system in use included a three-piece mechanical assembly...one component was sand cast in bronze, a second was produced from stainless steel rod, and a third was a stainless steel pin to lock the first two parts together.

A Sales Representative from Lofthouse became involved with the non-ferrous component, and after review, suggested the entire assembly could be forged into one part. His concept resulted in Lofthouse receiving a RFQ, complete with a sample of the assembly. Part-to-part consistency was a concern for the customer.

Challenge

In essence, the customer had two problems. As its product was overpriced in the market place, it hoped that forging would be less expensive than sand casting. In addition, the sand casting was cracking, leading to strength issues. An approach utilizing forging would have to exhibit superior mechanical strength properties that were greater than that of the current casting.

It was felt the forging alternative would be a price premium, but the customer wanted to proceed.

Solution

Lofthouse Engineering reviewed the assembly, and concluded that while the individual forged component would be slightly more expensive, a redesigned assembly netted fewer parts and would result in a stronger end product, ultimately at a reduced total cost.

The raw material selected was an aluminum-silicon-bronze (C64200), offering the right mix of strength, corrosion resistance, and cost. Lofthouse offered to tool the part at its expense, and collect the cost of tooling from the customer when the component met the agreed-upon mechanical requirements.

Not only did the single piece part meet requirements, it eliminated two drilling operations and the press fitting assembly operation by the customer. Overall cost of the assembly it replaced was reduced by 20%.

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