Detailed design missing details - Bennett Engineering

In this blog we identify how important value engineering is when you already have a CAD model for your product or machinery as our continuous improvement service. One of the areas that Bennett Engineering regularly get asked for support with is when a business already has some design work completed, and they have a set of CAD files. Now often these models are too complex, or the item has been manufactured and it’s been a nightmare to assemble. Or perhaps a quotation has been received that has made the product untenable to sell and make profit.

Sometime it could be that details are missing, a common one is the size of things, or it might be that materials have not been specified correctly, or assembly has not been thought about and the design is only great in the world of CAD and not the real world!

In this blog we review how Bennett Engineering undertakes project work such as this which is labelled under our continuous improvement / value engineering service offering.

Putting value into detailed designs

When a customer calls and says they have a CAD model for a design, but the assembly has been too complex, or they’ve tried to manufacture but the end result is not what the R&D or sales department was expecting we know that we can provide the design engineering needed to put things back on track.

Value engineering, or continuous improvement engineering, is a systematic approach of reviewing a model to improve the design. It could be that the functions are examined closely, the materials specified are respecified or the over engineering is removed. There’s lots of areas that Bennett Engineering have worked on and sometimes there’s multiple areas that are addressed.

This process is one that Bennett Engineering specialises in; our design engineers understand that commercially things need to be viable, whether it’s a cost effective manufacture of an item or an easy to assemble machine to reduce labour costs. Whenever we undertake a project in this area our clients achieve remarkable savings in materials, costs and assembly time whilst often enhancing product quality, reliability and functionality.

So, whilst it might seem like you have to pay all over again for a better CAD model what our advice would be is that you’re paying for experts who understand what you are looking to achieve in the real world and will provide you with that design.

The value engineering process for CAD Models

When you provide us with your existing CAD models, we will embark on a detailed analysis of your design. In short, your CAD model will be on our screens and every little detail will be looked at by our design engineers.

Not every project has the same approach but in most cases Bennett Engineering will complete:

Function analysis: we break down the product into its core functions, evaluating which features add value and which may be redundant or overly complex (what we call over engineered).
Material optimisation: by assessing the materials used in your design, we identify opportunities to substitute more cost-effective or sustainable alternatives without compromising quality or functionality. We’re not actively looking to save costs here we are seeking to reduce material usage which is one of the biggest waste streams that we see.
Design simplification: we reimagine components to reduce complexity, streamlining the design for easier manufacturing and assembly. We’re big fans of simple solutions to engineering challenges and like to use things like gravity which is free but works the same way.
Cost assessment: our team analyses every aspect of production and assembly costs, offering redesigns that significantly reduce expenses. We have examples of taking an OEM’s assembly time down from 6 weeks to just 1 from their investment in our value engineering services.
Collaboration with stakeholders: throughout the process, we collaborate closely with your team to ensure that the redesigned product aligns with your vision and requirements.

Key benefits of value engineering

Material savings

Our analysis often reveals opportunities to reduce material usage by:

Eliminating excess material through optimisation.
Replacing high-cost materials with less expensive, yet equally durable, alternatives.
Designing multi-functional components to reduce the need for additional parts.
Commonisation of parts and off the shelf components selected

Cost reduction

Value engineering uncovers hidden inefficiencies in manufacturing and material costs, such as:

Streamlining part designs to reduce machining time.
Simplifying tooling requirements for lower production expenses.
Standardising parts to minimise inventory costs.

Improved Assembly Efficiency

By redesigning CAD models with assembly in mind, our continuous improvement service will help:

Decrease the number of parts, making products easier to assemble.
Incorporate design features that reduce manual labour, such as snap-fit or modular designs.
Minimise the need for specialised tools during assembly.

Enhanced Product Performance

Optimising your detailed design often leads to improvements in performance and durability. This might include:

Reinforcing stress points in the design for better longevity.
Improving aerodynamics or ergonomics without increasing costs.
Enhancing modularity for easier maintenance and upgrades.

Sustainability gains

In today’s environmentally conscious world, continuous improvement can:

Reduce waste through efficient material usage.
Support greener manufacturing processes by using recyclable or biodegradable materials.
Lower the carbon footprint of your product over its lifecycle.

Real-world impact for continuous improvement

At Bennett Engineering, we’ve helped numerous clients achieve outstanding results through value engineering. For instance:

Consumer electronics: by value engineering the housing of a handheld device, we reduced material usage by 15% and assembly time by 20%, leading to significant cost savings for the manufacturer.
Automotive testing: we optimised a range of offline testing rigs used by automotive manufacturers across the world, cutting production costs by 12% for the OEM whilst improving operational integrity when in use and extending the lifespan of the equipment.
Industrial Machinery: through simplification of a machine’s design, we reduced its assembly time by 30%, enabling faster production cycles which improved sales for the manufacturer.

Partner with Bennett Engineering for Smarter Designs

Whether you’re looking to refine an existing product or address challenges in manufacturing, value engineering can unlock new levels of efficiency and performance. At Bennett Engineering, we combine knowledge, understanding and a breadth of engineering expertise with a commitment to delivering tailored solutions that meet your unique needs.

Continuous improvement as a service can totally transform your CAD models into optimised designs that save materials, reduce costs, and improve assembly efficiency, all while enhancing the overall value of your product.