DFF Case Studies
Read our precision machining case studies that detail how our precise manufacturing and engineering made an organizational impact for our customers through their real-life accounts.
Each story is presented in a problem / solution / results manner to give a glimpse into the types of specialized solutions and strategies that may someday benefit your own facility.
ASSEMBLY CASE STUDY
In this case study, you’ll discover how our assembly services rival that of our competitors, and the ways in which they benefit our customers. When you partner with us, you’ll gain access to:
- A team of driven and tenured professionals.
- A Visual Factory facility with prominent signage and bright LED lights to ease eye strain, and improve concentration and accuracy.
- The ability to accomplish highly technical assemblies with the latest technology, tools and equipment.
- The same results achieved by our other customers and our commitment to quality.
We are always willing to help our customers with design improvements. In addition to access to 250 primary vendors, we possess the experience, equipment, resources and knowledge to offer sound recommendations to improve products and processes—while reducing costs. Click the button below to learn more about our assembly services.
In Vitro Diagnostics Case Study
A longtime customer, an in vitro diagnostics company with a successful 75-year history, was experiencing a higher than desired failure rate on a highly sought-after and regulated blood analyzer.
DFF reverse engineered the 300-part assembly, diagnosing a design modification that would improve accuracy and meet FDA regulations.
Production of the blood analyzer has doubled.
Stator Housing Case Study
Our customer, a leader in the electric propulsion ground vehicle market, was in need of a more efficient and effective manufacturing process for a stator housing sub-assembly designed for large hybrid electric motors.
DFF developed a new process of thermal shrink-fitting to eliminate stresses on
Pleased with the results, the customer approved the assembly and awarded DFF the BETA run for production, and the opportunity to produce another stator housing assembly already in production.
FMS Case Study
Here at DFF, our flexible manufacturing system (FMS) capabilities allow us to support customers who require overflow production or regularly need specific parts. In this case study, you’ll discover the benefits of partnering with us in an FMS capacity:
- Reduced labor costs with our lights-out machining capabilities in our modern, climate-controlled facility.
- An array of available machinery to accommodate low volume/high mix set ups with little notice.
- Machines that operate efficiently under 24/7 production to meet your needs.
We are always willing to help our customers with design improvements, and possess the experience, equipment, resources and knowledge to offer sound recommendations to improve products and processes—while reducing costs. Click the button below to learn more about our flexible manufacturing system.
A Focus on Quality and Critical Dimensions
A global leader in the semiconductor industry was dissatisfied with the quality of high vacuum chambers being produced by a manufacturing partner.
DFF was solicited to remedy the issue, ultimately developing chambers that stood up to strict helium leak detection tests and passed real-world testing with flying colors.
Pleased with the success of the initial partnership, the company turned to DFF to produce a second set of specialized parts, which likewise passed strict testing requirements.
SAVING GREEN WHILE GOING GREEN
A longtime customer, and leader in the electric propulsion ground vehicle market was experiencing a higher than desired failure rate on their thermal management system (TMS), a box that cools batteries on their line of hybrid electric buses.
DFM services from DFF: a thorough review of the part revealed the reason for the failure, which DFF addressed through design and production improvements.
A system with a longer lifespan and significantly reduced failure rate.