Observations and Solutions
During a technical line review of a customer’s facility, the Field team observed the components and methods of manufacturing used to assemble a railcar. The following observations were made with corresponding solutions:
- The Field team observed several fasteners extending farther than necessary beyond the rear nut
- Increased cost of fastener due to extra material
- Takes extra time to assemble the fasteners
Solution: Shorten the lengths of 3 of these fasteners
TOTAL OPPORTUNITY: 242 labor hours and $5000 in annual fastener costs
- Current practice is to tack weld eyebolts to prevent them from being removed
- Tack welding offers uncontrollable heat distribution that could weaken the metal
- Weld splatters can occur in undesirable area
Solution: Replace the tack welded threads with a drilled hole and drive pin
TOTAL OPPORTUNITY: $48,000 annually
- Current practice is to use a cross pin design to secure eyebolts that are then tack welded
- Tack welding a bolt can have an adverse effect on the mechanical properties of the bolt
Solution: Replace cross pin design with a safety collar design
TOTAL OPPORTUNITY: $12,000 annually
Results
The Field team recommendations provide improved quality and reduced total costs through:
- Reduced assembly time
- Reduced material costs
- Improved mechanical stability
- Simplified field maintenance
- Part standardization