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Redesign of Display Window Frame Results in Big Savings

	BENEFITS IN BRIEF: • Higher quality at lower cost • Secondary processes eliminated • 3-to-1 reduction in part count • Reduced cycle time
	Maysteel redesign (above) resulted in clean, one-piece frame with no welds or sharp protrusions.
	Original design, requiring three pieces and numerous welds, also left potentially dangerous corner protrusions

Apr 2004

What may have seemed a relatively inconsequential part within a large enclosure became a significant opportunity for savings as a result of Maysteel's design-for-manufacturability efforts.

As originally configured, the display window frame was built from three separate pieces of sheet metal, requiring 10 TIG tack welds to join, plus additional grinding and deburring steps. The assembly process also left sharp corner protrusions that, while not exposed to server users, could pose a hazard to assemblers and service personnel.

Maysteel's redesign allowed the frame to be formed from a single piece of sheet metal utilizing one manufacturing process. The resulting unified frame is not only much easier, quicker and cheaper to manufacture but also represents a major improvement in aesthetics and safety.