Barry-Wehmiller Network
Equipment Design Solutions

Project Profiles

Please see the below Project Profiles representing Design Group Equipment Design Solutions.

  • Food and Beverage Manufacturer

    REDESIGN: Cost Optimization and Standardization for Food and Beverage Manufacturer

    Client Profile:
    The client is a global supplier of food and beverage products.

    Design Group Scope of Work:

    • Optimize cost and reduce number of product variants
    • Ensure global availability of replacement parts

    Approach:

    • Performed value engineering on mechanical and electrical parts – motors, tapping blades, mounting brackets
    • Standardized design for reducing the product variants

    Results:

    • Cost of the unit reduced by 60%
    • Reduced number of product variants from five to two
    • Use of off-the-shelf parts ensured availability of spares globally
  • Food Processing Machinery

    REDESIGN: Design Product Variants for Industrial Slicing Systems Manufacturer

    Client Profile:
    The client is a manufacturer of industrial slicing systems for meat products.

    Design Group Scope of Work:
    Design machine variants that suit market requirements in Europe and US

    Approach:

    • Studied existing machine and regional standards
    • Identified modules for standardization
    • Redesigned modules and reviewed design 
    • Finalized design and released drawings for manufacturing

    Results:

    • Product yield higher by 7% and pack weight accuracy
    • Modular design for quick changeover and minimum footprint
  • Industrial Products

    REDESIGN: Cost Reduction for Industrial Products Manufacturer

    Client Profile:
    The client is a leading manufacturer in the transmission industry.

    Design Group Scope of Work:
    Design and develop customized electrical poles that meet regional requirements

    Approach

    • Studied end-client specific engineering standards and client's manufacturing process
    • Created and reviewed engineering design 
    • Released drawings for manufacturing

    Results:

    • Reduced engineering costs and turnaround time
    • Enabled direct release to fabrication shop
  • Consumer Packaged Goods

    RETROFIT: Safety upgrades for Consumer Packaged Goods Manufacturer

    Client Profile:
    The client is a leading consumer packaged goods manufacturer.

    Design Group Scope of Work:
    Provide safety guarding around hazardous areas on chilled roll machine

    Approach:

    • Reviewed existing design and generated concepts
    • Reviewed and shortlisted concepts
    • Finalized design and reviewed with risk assessment team
    • Created detailed design and manufacturing drawings

    Results:

    • Addressed the issues from risk assessment
    • Ensured compliance to safety standards
    • Created maintenance friendly design
  • Industrial Cleaning Wipes

    RETROFIT: Safety Upgrades for Industrial Cleaning Wipes Manufacturer

    Client Profile:
    The client is manufacturer of contamination control products for manufacturing environment.

    Design Group Scope of Work:
    Develop vapor containment guarding around machine

    Approach:

    • Reviewed existing design and generated concepts
    • Reviewed and shortlisted concepts
    • Created detailed design and manufacturing drawings

    Results:

    • Enabled easy maintenance of machine
    • Provided safer environment for plant personnel
  • Packaging Machinery

    REDESIGN: Modularization and Cost Optimization for Packaging Machinery Manufacturer

    Client Profile:
    The client is a manufacturer of packaging machinery for the food and beverage industry.

    Design Group Scope of Work:
    Facilitate global expansion of equipment through modularization and cost optimization

    Approach:

    • Reviewed existing design and other available modules with the client
    • Identified potential for modularization and cost optimization
    • Ensured adherence to NSF standards of the proposed design

    Results:

    • Implemented firm-wide modularization
    • Realized cost benefits of up to 30%
  • Pharma Production Line

    REDESIGN: Improved Capacity of Packaging Line for Pharmaceutical Manufacturer

    Client Profile:
    The client is a leader in manufacturing and packaging of pharmaceutical products.

    Design Group Scope of Work: 
    Enable effective use of floor space for improved throughput and automation

    Approach:

    • Reviewed takt time for line balancing; new line layout for eliminating unwanted product handling
    • Redesigned machine elements for improving productivity – added accumulators, pushers, shingling devices, carton orientation and conveying elements

    Results:

    • Increased throughput by 20%
    • Reduced floor space by 35%
  • Hygiene Disposables Manufacturer

    REDESIGN: Cost Reduction for Hygiene Disposables Manufacturing Machinery

    Client Profile:
    The client is a manufacturer of special purpose machines for hygiene disposables.

    Design Group Scope of Work:
    Redesign a competitive and cost effective hygiene disposables manufacturing machine

    Approach:

    • Performed VAVE analysis of the module to identify cost saving potential
    • Created alternative design for fixing quality issues

    Results:

    • Reduced part count by more than 75%
    • Reduced material cost by 80%
    • Removed equipment down time and improved OEE
  • Horizontal Flow Wrapper Machinery

    REVERSE ENGINEERING: Cost Optimization for Horizontal Flow Wrapper Machine

    Client Profile:
    The client is a global supplier of food packaging machinery.

    Design Group Scope of Work:
    Reverse engineer an existing equipment for competitive benchmarking

    Approach: 

    • Created wire frame models based on technical manuals provided
    • Updated models for actual dimensions upon receipt of the machine
    • Used 3D scanning technologies for reverse engineering complex parts

    Results:

    • Enabled quick turnaround time of five weeks, 300+ parts
    • Released drawings for longer lead time items in the first phase for shrinking the schedule
  • Diagnostic and Screening Devices

    REVERSE ENGINEERING: New machine design for diagnostic screening device

    Client Profile:
    A biotechnology company that manufactures screening devices for medical professionals and patients.

    Design Group Scope of Work:
    Reverse engineer an existing obsolete machine for improving productivity

    Approach:

    • Conducted on-site study and requirement gathering of the machine 
    • Prepared URS, FRS and Traceability matrix to ensure machine specifications are met
    • Proposed solution using off-the shelf solutions and custom designs as required
    • Reviewed and finalized design

    Results:

    • Reverse engineered an obsolete machine to establish a second foot print
    • Designed new equipment that meets the defined cost target
    • Increased productivity