Solving Design Issues

EC Styberg has over 80 years of experience solving design problems for medium and heavy gauge simple to complex metal components. We produce to individual customer's requirements. Production lots normally range from 250 units on up. On special occasions we do produce less than our normal run, but those are usually very complex parts. Test our Concurrent Engineering program, for we feel we can help you with your toughest design challenges. Prototyping is available, for Styberg Engineering has a full compliment of tools to produce prototypes. A full Tool and Die Department with many pieces of CNC machining and seasonal Tool and Die Journeymen. This along with our Concurrent Engineering program allows even more Customer satisfaction, including:

Manufacturing Cost Reduction
Styberg can review your present or new designs and provide new ideas to help with manufacturing cost reduction. The cost reduction can be realized by reducing manufacturing operations, material weight and/or components used on the final product.

Examples of our manufacturing cost reduction include:

1. We took a 32 pound spline down to a 12 pound casting and made it out of coil stock while still holding all spline dimensions. This reduced stock weight but also timely Manufacturing Operations.

2. We reviewed a customer designed wheel that needed to be lighter weight but also required a higher tensile strength. We reduced the wheel weight by 10 pounds, but also increased the tensile strength by 100%.

3. We re-designed a two and a three-piece customer design and made both into one-piece design. This allowed less material, less manufacturing operations and increases a single component strength. All in a one piece design.

All of this can be done because of our design skills and that we have many different manufacturing processes under one roof.

In coordination with manufacturing operations, material weight and overall strengths we also keep in mind:

Dimensional Consideration
We review component dimensions to look for time and cost savings for our customers. The easier a part can be designed the risk of dimensional errors will be reduced, resulting in a major reduction in your overall cost, and this is a major advantage for errorproofing, standardization and overall improved quality. Whether it's reducing the number of operations or converting from a casting into a deep drawn form, when there are fewer operations there are less risks for dimensional errors and less inspection time.

Process Simplification
With the capabilities of designing for cost and weight reductions, one element that we keep in mind at all times is process simplification. Designing with simpler and fewer operations results in lower cost and fewer errors in the overall system.

We have used these considerations to take a three-piece construction and convert it into a one-piece using fewer operations, less errors and cost reductions. This process has been used by taking three piece weldments and making them into a one-piece construction or by taking three separate parts and converting them into a single operation and changing casting or forging into coil steel production, this lead to less machining, lower tooling costs and reduction material. The list of success stories is endless, and they include the use of Deep Drawing, Stamping, Heat Treating, Machining, Welding, Spotwelding operations to just include a few.