Original Equipment Manufacturer

Improve the manufacturing process for a 3 chamber muffler assembly.

The OEM designed muffler assembly had not yet been scheduled into production. Baffles inside the chamber were not easily located. In addition, customer tolerances on the drawing were driving cost above target.

D&S worked with the customer’s engineering staff to design steps inside the chamber to positively locate baffles. To maintain tight tolerances on the height of each port, the diameter of the baffle ports was changed to accommodate machine steps in 11 baffles on each plate.

The dimensioning on 2 couplings mandated that they be located and machined after welding. It was determined that these were compression gages and therefore did not need to be toleranced as tightly. The tolerances were subsequently increased and the production cost was reduced. D&S also internally designed tooling for welding, machining, and assembly operations.

As a result of this collaboration, the customer will receive parts that meet quality requirements at a lower cost and within shorter lead times.