Customer Challenge: Our challenge was to improve this product to reduce the 25% failure rate generated by the required assembly process of the two pieces. Stalcop’s Solution: In addition to this part configuration generating a high (25%) failure rate, it was also extremely costly to manufacture. There was a machining process required to connect a…

Customer Challenge: Our challenge was to improve this product, which had multiple failure modes along with a very high material cost. Our goals were to correct the failure problems and to fix the operating cost for the manufacturing of this part. Stalcop’s Solution: This component started as an assembly of two machined and formed parts…

Customer Challenge: Offering substantial cost reduction while maintaining or enhancing two product features. One of the early challenges for Stalcop was to convert a product made from a screw machine to a cold headed version, while maintaining or improving some key product features and functions. The features required were an anti-rotation and anti-extraction accomplished by…