Areas of Engineering
Customer C encountered high costs and performance difficulties with a large diameter headed bolt used as a spring pin in a leaf spring suspension application. The spring pin was required to fit the sleeve with close tolerances and little movement once installed. Furthermore, the spring pin was required to have rolled threads that were the same diameter as the shaft to fit into the sleeve during assembly. McCoy Bolt Works developed a double-end threaded rod with consistent diameters for the rolled threads and shaft. McCoy supplies the part with a nut on one end at a cost 12.2% below the previous head bolt part. Dimensional and strength tests were performed by McCoy to develop and refine the concept.
McCoy Bolt Works proposed metallurgical and process changes for a suspension u-bolt parts family used by Customer D in high volume Class 8 tractor rear suspensions. McCoy Bolt performed strength and assembly tests to prove the merit of the concept for the Customer to validate through test track performance. The design changes saved 8%-10% in part costs, which saved Customer D in excess of 3% of the total annual suspension u-bolt purchase.
Customer D encountered high assembly and rework costs for battery holding bolts slipping through feed slots in the battery holding trays prior to engagement with the nuts. McCoy Bolt Works developed a battery hold bolt with tabs on the shaft to prevent slipping, and also developed an automatic machine to cost effectively manufacture the parts. The battery hold parts cost 50% more, which is more than offset by assembly labor savings so that Customer D experienced a net cost reduction.