Our client was looking to design and build an interactive screen for the children’s education sector. The client had been underwhelmed by previous subcontract fabrication partners and was in the market to find a better solution, with an opportunity to improve quality, communication, and a partner that could react quickly and keep up with demand.
Elecon was engaged right from the early design stage and offered concepts to get the project underway, which once approved by the client led onto the prototyping stage. The design incorporated a combination of metal fabrication, high-tech touch screens, and required an extremely high commercial powder coat finish.
Once the final design was approved, and commercials were agreed, Elecon moved to the production stage, and these are the core processes required.
Processes Elecon Used:
- Design and Prototyping: Collaborated on creating the design brief and shared ideas on concepts and designs to kickstart the project.
- File Upload and Management: Utilised a Trumpf business management software platform for efficient file handling.
- Laser Cutting: Employed a Trumpf 5kw fibre laser cutter to precisely cut assembly kit components while optimising sheet utilisation and minimising waste.
- Nut Insertion: Used a Heagar nut insertion machine for inserting studs and nuts into certain parts of the assembly kit.
- Sheet Folding: Utilised Trumpf folding machines for bending and shaping components using multi-axis CNC Press Brakes with a high press force.
- Welding: Employed MIG or TIG welding as required for different project specifications.
- Pre-Paint Preparation: Utilised a phosphate wash process to clean and degrease metal surfaces before powder coating.
- Powder Coating: Operated an in-house powder coating facility with the ability to apply various finishes and colours, ensuring full control over lead times and quality.
- Assembly: Completed assembly of the base with a powder coat finish prior to the second fix of electronic components and high-tech touch screens.
- Quality Control (QC): Conducted a final QC check before moving the completed unit to the packaging and distribution department.
- Packaging and Distribution: Provided multiple packaging solutions and distribution options, including large curtain-sided vehicles and a smaller fleet of delivery vans.
Client Feedback:
The client expressed satisfaction with the project execution:
- Communication throughout the project was described as timely, consistent, highly informative, and going the extra mile.
- Quality surpassed previous experiences.
- The project met all commercial requirements, and the product was successfully launched in the market and is still being sold today.
- Elecon has gone on to work on numerous technically challenging projects.
- Elecon has developed a strong relationship over the last four years.
Achievements:
Elecon successfully achieved the following outcomes for the client:
- Successfully supported the design and prototyping stages.
- Transitioned from concept to market launch with a commercially viable product.
- Achieved a consistent powder coating quality, ensuring a premium finish.
- Demonstrated excellent communication and support with the client throughout the project.
Client Testimonial: Any business looking to source a fine-limit metal fabrication subcontract company with a high level of technical knowledge should look no further than Elecon.
Appreciating the work we undertake for clients is of a highly confidential nature, we are happy to organise references with the clients referred to in our case studies, but subject to prior our client approval.
