THE CHALLENGE
A technically workable process with unnecessary complexity
A Tier-1 aerospace manufacturer used 13 individual fixtures to produce a thin-walled aerospace casing.
The process worked, but it created high tooling cost, multiple re-clamping operations, longer manufacturing time, more handling risk on fragile geometry, and limited flexibility if the design changed.
High tooling cost across 13 fixtures
Multiple re-clamping operations
Longer manufacturing time
High tooling cost across 13 fixtures
Limited flexibility if the design changed
THE APPROACH
Reviewing which stages genuinely needed dedicated tooling
Cobig reviewed the full manufacturing process, challenged the existing approach, and identified where operations could be combined without adding risk.
Dedicated fixtures kept only where needed
Modular fixture approach introduced where practical
Process complexity reduced
Clear visibility before changes were made
THE RESULT
A simpler production architecture with measurable gains
Tooling investment
£62,000 ➔ £52,500
18.1% reductiom
Manufacturing time
330min ➔ 265min
24.5% reductiom
Parts count
13 fixtures ➔ 7 fixtures
46% reduction in parts count
The client approved the revised approach and proceeded to manufacture with a clearer, lower-complexity production strategy.
Additional benefits included:
Reduced handling risk
Improved repeatability
Fewer changeovers
Greater flexibility for future design change
WHAT THIS DEMONSTRATES
What this demonstrates
The value was not in redesigning everything from scratch. It came from stepping back, challenging the current approach, and identifying where cost and complexity could be removed with losing the intended outcome.
