L125 Cost Reduction DFMA Fred, Donna, Lauri, Stanley, Kathy February 5, 2015.

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Presentation transcript:

L125 Cost Reduction DFMA Fred, Donna, Lauri, Stanley, Kathy February 5, 2015

Assumptions

4 foot LED fixture (one row of LED fixtures) Standard driver - no DME/DM3 driver (heat transfer pad needed for Lutron) Life volume 10,000 (4 foot units) Labor Rate $40/hr Plant efficiency 85%

Results

Safe Redesigned extrusion to accommodate screw channels Eliminated terminal block mounting bracket and screws Eliminated ballast mounting bracket and screws Channel for boards to slide in – eliminated 15 push rivets Redesign LED board – one sized board rather than two Eliminated extra wiring and labor (less connections / failures) Eliminated ballast disconnect Stretch All of the above plus: Redesigned door frame to a hinged design Eliminated door frame endcaps and screws Made glass thicker Push fit end cap for housing Added gasket, eliminated silicone and transport time, and screws Needs reworked design for housing end cap

Recommendations, Risks, and Plans

Eliminate machining from housing (for housing gasket) DFM result is removing $3.67 cost from housing (safe and stretch) Risk: requires some development work and new endcap for housing

Eliminate machining from door frame rail (for door gasket) DFM result is removing $6.42 cost from housing (safe) Risk: requires some development work and new endcap for door

Sheet Metal vs. Extruded gear tray comparison plus cost for anodizing DFM result is adding per foot cost, but eliminates mounting brackets, rivets, and some wiring Risk: requires some development work plus cost of tooling $1.02/ft $2.20/ft

Other ideas/ risks Relocate driver to gear tray from housing (might help wire maintenance) Make housing and endcaps one piece (different sizes more difficult) Door frame using clips to snap into housing (eliminates screws) Further housing endcap redesign to eliminate gasket and screws altogether (water tight?) Door frame redesigned to one piece unit Door frame held together with something besides screws (would require new press/machine) Lens snap into the housing to eliminate the frame Reduce offering to fewer lengths Eliminate the terminal block or reduce the number to one