Designing for Manufacturability: Sanborn Print Reviews Save OEMs on Delivery Times and Part Costs

New product designers focus their efforts on achieving the best in functionality, usability and aesthetics. However, manufacturability is not always considered in that process. To help with that effort, Sanborn uses its expertise in the tube and pipe industry to identify more cost-effective and readily available options, saving customers time and money.

During the RFQ process, Sanborn conducts a print review to find tube options that are easy to find and priced within the budget. Although Sanborn is design exempt, the company may recommend a switch to a different pipe solution that provides the same results in the final product. 

Using the company’s long-standing tube and pipe expertise, in-house part fabrication capabilities and wide network of suppliers, Sanborn often finds ways for customers to make a more manufacturable tubular part.

“We advise customers to avoid painting themselves in a corner by specifying tube and pipe that can be unnecessarily expensive or difficult to source,” says Chad. “Shortages and higher prices can become an even bigger problem down the road, causing costly production delays or product redesigns. We want to steer OEMs toward using tubes that will take those risks out of the equation.”

During a print review, Sanborn often finds multiple ways to take out extra costs or availability problems for a tubular part:

Consolidate components

Look for opportunities to use a single tube instead of multiples. For example, instead of welding

two angled pipes together, Sanborn can bend a single tube and achieve the same performance. This change can potentially save on delivery time and costs for pipe, weld fixturing and labor. Plus, Sanborn has invested in fiber tube lasers that can cut notches or other shapes in areas of a pipe that was previously inaccessible.

Use a common tube size

During a print review, Sanborn will research the best prices from suppliers. In some cases, a non-standard tube, which can be costly and harder to source, can be replaced by a standard sized tube and still achieve the same performance and appearance.  For example, Sanborn received an RFQ for the tube components of a metal chair. The designer specified a 1.25-inch rectangle tube for the frame and legs. That tube style was not readily available and would delay production. Sanborn recommended switching to the more standard 1.5-inch rectangle tube which could be sourced quickly and continually so production could begin on time.

Convert from metric

Products designed outside of the United States are more likely to have tube and pipe measurements specified in metric. For sourcing pipe within the U.S., the standard imperial system of measurement is more useful. Sanborn works with customers to convert their specs to inches and feet to find the most common and cost-effective option. For example, a tube specified at 25 mm can be converted to a slightly higher 1-in. tube because it is easier to source domestically.

Standardize across product lines

If an OEM is making several products with similar tubes, it may be more cost effective to standardize on a single tube size and shape. This allows Sanborn to source the pipe in higher quantities for discounted prices.

DOM vs ERW

Some engineers specify a drawn over mandrel (DOM) tube for parts that require tight tolerances and higher strength. However, technological advances have made it possible to get better tolerance and strength from standard electric resistance welded (ERW) tubes than was available in the past. Whenever possible, Sanborn looks for lower priced ERW tubes that achieve the same required tolerances as a specified DOM tube but at 1/3 the price.    

For better manufacturability, OEMs can get Sanborn involved earlier in the product development process to provide recommendations on available and cost-effective tube and pipe options. This saves time and avoids potential redesign steps that may slow down a product launch.

Contact Sanborn to learn more about way to save time and costs in your tubular parts.