Cracking Welds and Collaboration Case Study

A manufacturer of industrial wash systems was looking for a way to gain a competitive advantage over another manufacturer using the same process to produce a similar product. There were legacy issues with the product, including cracking and deforming welds due to vibration, that caused increased operating costs for the end user. The manufacturer sought a new group with strong engineering capabilities to gain outside expertise on some of these issues.

Wes-Tech offered collaborative engineering services, including discovery, advisement, and defining ways to streamline the product for manufacturability while improving the system's capabilities. Rather than a defined scope of work, Wes-Tech was willing to partner with the customer on a time-and-materials basis. Wes-Tech acted as an extension of their team and worked closely with the engineering lead on the customer side.

The Wes-Tech team began by completing a Finite Element Analysis (FEA) on the framework, with the goal of helping the manufacturer design the issues out of the product for the future. The time-and-material basis allowed Wes-Tech to collaborate on any needs, even if they went beyond the specific issue of cracking welds.

Wes-Tech met regularly with the customer—at a daily or weekly cadence, depending on needs—for updates, had frequent calls and discussions, and kept the customer in the loop at every step of the process. Transparency was a big part of making this consulting model work. The customer always knew how hours were being managed, and the Wes-Tech team made sure to stay on time and within budget.

Wes-Tech solved the issue with the welds and went beyond the initial request to complete related tasks. For example, once the manufacturer had built the new design, Wes-Tech returned to help them deploy the updated product for one of their customers. Wes-Tech also converted the customer's legacy CAD data into an updated 3D model, which the customer could then leverage for manufacturing, maintenance, operating manuals, and more.

Working within a time-and-materials model allowed the Wes-Tech team to behave as a true extension of the manufacturer’s engineering team. Consistent transparency around hours spent ensured Wes-Tech stayed within budget, and the collaborative nature of the process ensured the customer got results, including:

• Reduced downtime of the equipment, leading to uninterrupted production and higher throughput.
• Help on issues they had not asked for but did need, showcasing Wes-Tech’s proactive approach and deep understanding of their customer’s operations.
• A partnership that translated to more projects in the works, indicating a mutual trust and shared vision for future success.
• Increased end-user satisfaction with lower maintenance costs, reflecting the direct benefits passed on to the consumers.
• A competitive advantage was achieved by improving the product design over what their competitors were using, ensuring the manufacturer remains at the forefront of innovation.

This collaborative project exemplifies how Wes-Tech’s dedication to their craft and their customer’s success has delivered immediate benefits and laid the groundwork for enduring growth and innovation. It is a clear demonstration of how strategic partnerships can lead to breakthroughs that drive collective advancement.