How This Truck Manufacturer Improved Acoustic Engineering Without Additional Payroll Expense

This American vehicle company is the leading producer of aluminum walk-in vans and truck bodies used for delivery and cargo vehicles. In addition to delivery trucks and mobile workshops, customers include fleets that deliver baked goods, laundry, and newspapers.

Challenge:

  • Reduce the sound issues inherent in the aluminum structure of their sturdy, but noisy, vehicles – to ensure the safety and comfort of the drivers.
  • Assure a consistent supply chain process by developing a new modern product moving the client from an outdated foam-based product to fiber, improving performance.
  • Eliminate the need for a manufacturing cell lowering TCO.
  • Develop a superior protective material to prevent flammable accidents.

“If we have an acoustics issue, we will reach out to Blachford since they are the experts. It saves us money, because we do not have to keep an acoustic expert on site with an annual salary, with benefits, of $125K.”

– Design Engineer

Solution:

Provided acoustics expertise through knowledge sharing, onsite testing and access to the Blachford in-house acoustics lab, reducing sound issues inherent in the aluminum structure of their sturdy, but noisy, vehicles. Improved safety and comfort for drivers while eliminating the need for an in-house acoustics engineer, saving $125K annually.

Proactively replaced obsolete foam-based acoustics material with a modern material formulation specifically engineered to improve heat performance. Proactive approach ensured zero disruption to the production.

Innovative die-cut product design eliminated an entire shop floor manufacturing cell saving $100K annually.

Avoided significant liability expense and embarrassment through Blachford’s ability to create an engine enclosure which would not absorb engine oil. Previous materials absorbed oil resulting in a combustible event.

“We reported [purchasing department] savings of $100k annually from moving to the die cut solution using Blachford”

– Design Engineer

Expected Annualized Benefits:

  • Eliminated need for an acoustics engineer saving $125K
  • Simplify manufacturing process savings of $100k
    • Achieved appropriate sound level reductions improved safety and comfort
    • Simplified assembly and reduced mistakes
    • Less-flammable materials provide safety and protection from legal liabilities

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Case Study Snapshot:

Customer Industry:

Truck Manufacturing

Annual Revenue:

325 Million

Total Employees:

950

Business Issues:

  • Achieve satisfactory sound levels in aluminum transportation vehicles
  • Meet customer expectations for driving safety and comfort
  • Maintain acoustics engineer expertise as needed without payroll expense
  • Maintain supply chain materials avoiding expensive production shutdowns
  • Simplify cellular manufacturing, improving throughput and lowering cost
  • Protect property and life with less-flammable materials

Key Results:

  • Saved $125k in Engineering Costs
  • Simplified Production Line to Save $100k
  • Simplified Supply Chain
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Customers Who Trust Blachford Acoustics Group

“Blachford eliminated SKUs. Across product families, the reduction of one SKU is a $10k savings. Blachford eliminated 14 SKUs.”

– Noise Control Research Engineer – Construction Equipment Manufacturer

“The first project with Blachford, it was a definite quality improvement, and it was over a million dollar yearly cost savings for just the purchase parts themselves. We went from 28 (SKU) parts to 14.”

– Design Engineer – Heavy Equipment Manufacturer

“Noise is important to brand image. It is one of the top factors along with driveability and reliability. Acoustics – it’s a 4 out of 5, it might even be a 5 in importance projecting the image, the brand, and the quality that we want projected to the market.”

– Design Engineer – Truck Manufacturer

“Our ten-fold growth prior to our acquisition was expedited by our working relationship with Blachford.”

– Design Engineer

“For our shareholders, we have to produce a product at the lowest cost, at the right level of quality and sell it at the highest price we can. We look for suppliers who can help us do that. Blachford helps us do that.”

– Global Procurement Manager – Construction Equipment Manufacturer

“When a company does a spec, boundary conditions like humidity that day, temperature, that all matters. ASPM national or international spec. We try to verify where we can, but we don’t even have the equipment they have. We trust their specifications. Blachford brings innovative ideas, processes, materials, and offerings we value.”

– Design Engineer – Truck Manufacturer

“Then, bringing them in at the beginning with our new product design, it probably saved 6-12 months of development. We didn’t just wa nt the spec sheet value. We wanted customers to get in the machine and experience the difference.”

– Design Engineer – Heavy Equipment Manufacturer

“If we have an acoustics issue, we will reach out to Blachford since they are the experts. It saves us money because we do not have to keep an acoustic expert on site with an annual salary, with benefits, of $125K.”

– Design Engineer – Truck Manufacturer

“As a mechanical engineer, we make stuff that is practical and affordable and Blachford’s materials routinely help me reach these goals.”

– Design Engineer

“We [purchasing department] reported savings of $100k annually from moving to the die-cut solution using Blachford.”

– Design Engineer – Truck Manufacturer

Customers Who Trust Blachford Acoustics Group

“Blachford eliminated SKUs. Across product families, the reduction of one SKU is a $10k savings. Blachford eliminated 14 SKUs.”

– Noise Control Research Engineer – Construction Equipment Manufacturer

“The first project with Blachford, it was a definite quality improvement, and it was over a million dollar yearly cost savings for just the purchase parts themselves. We went from 28 (SKU) parts to 14.”

– Design Engineer – Heavy Equipment Manufacturer

“Noise is important to brand image. It is one of the top factors along with driveability and reliability. Acoustics – it’s a 4 out of 5, it might even be a 5 in importance projecting the image, the brand, and the quality that we want projected to the market.”

– Design Engineer – Truck Manufacturer

“Our ten-fold growth prior to our acquisition was expedited by our working relationship with Blachford.”

– Design Engineer

“For our shareholders, we have to produce a product at the lowest cost, at the right level of quality and sell it at the highest price we can. We look for suppliers who can help us do that. Blachford helps us do that.”

– Global Procurement Manager – Construction Equipment Manufacturer

“When a company does a spec, boundary conditions like humidity that day, temperature, that all matters. ASPM national or international spec. We try to verify where we can, but we don’t even have the equipment they have. We trust their specifications. Blachford brings innovative ideas, processes, materials, and offerings we value.”

– Design Engineer – Truck Manufacturer

“Then, bringing them in at the beginning with our new product design, it probably saved 6-12 months of development. We didn’t just wa nt the spec sheet value. We wanted customers to get in the machine and experience the difference.”

– Design Engineer – Heavy Equipment Manufacturer

“If we have an acoustics issue, we will reach out to Blachford since they are the experts. It saves us money because we do not have to keep an acoustic expert on site with an annual salary, with benefits, of $125K.”

– Design Engineer – Truck Manufacturer

“As a mechanical engineer, we make stuff that is practical and affordable and Blachford’s materials routinely help me reach these goals.”

– Design Engineer

“We [purchasing department] reported savings of $100k annually from moving to the die-cut solution using Blachford.”

– Design Engineer – Truck Manufacturer

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STEP 1:

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Give us some basic information about your sound, vibration or thermal reduction goals.

STEP 2:

COLLABORATE WITH OUR EXPERTS

Our team of engineers will work with you to uncover all issues and identify possible solutions.

STEP 3:

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We will design, fabricate and lab test solutions to improve the performance of your products.

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