Table of Contents
Background
An equipment manufacturer facing high warranty claims and operational costs due to hydraulic system failures approached a technical services firm with experience in hydraulic systems. The issues were primarily related to hydraulic hose and tube routing connection integrity and an overly complex hydraulic circuit, which affected the equipment’s reliability and performance.
Objective
The technical services firm’s primary objective was to identify the root causes of the hydraulic failures and devise a strategy for hydraulic system improvements to reduce warranty claims. Additionally, the client requested that the strategy include an organized approach to reduce the product cost compared to the current design.
Team Composition
The project team included a hydraulic engineer, a CAD routing engineer, a warranty/cost analyst, and a project engineer. They were responsible for the comprehensive assessment, solution development, and implementation guidance.
Assessment Phase
The team’s initial step at the manufacturing facility involved several steps.
- Evaluating the existing hydraulic routing diagrams and installation processes.
- Analyzing warranty claims, factory first pass yield failures, and failure modes related to the hydraulic systems.
- A factory visit to review the entire process and final product assembly quality.
- Interviews with the vehicle product development and test teams.
Findings
The investigation highlighted several critical issues.
- Complex and inefficient hydraulic routing leads to vibration and usage failures.
- Poorly routed hose connections lead to hose failures and leaks.
- Excessive use of adaptors.
- Inadequate use of manifolds to reduce part count and leak points.
- Inadequate protection against environmental hazards such as debris and temperature extremes.
- Need for adequate retention and support.
Proposed Solutions
To tackle these issues, the team proposed a series of strategic changes.
Routing Optimization
- Redesign the hydraulic routing to minimize bends, reduce pressure loss, and eliminate stress points.
- Introduce more robust mounting brackets to secure hoses and tubes away from potential damage zones.
- Replace multiple fitting junctions with manifolds.
- Simplify the routing across the machine to be more efficient and easier to assemble.
- Part count reduction.
Connection Upgrades
- Recommended using a more conventional bend radius and straight lengths along with improved tool access to improve assembly quality.
Protective Measures
- Implement protective sleeves and guards around hoses to shield them from environmental damage and mechanical impact.
Implementation
The team developed the design and created the part drawings for release for the prototype. With the manufacturer’s collaboration, the team oversaw the implementation of these improvements in a prototype build.
Conclusion
The hydraulic system enhancements were projected to reduce warranty claims due to fewer failures and lower overall operational costs through improved system reliability and reduced downtime. Additionally, the changes provided several hundred dollars in product cost reduction. This initiative aimed to boost customer trust and satisfaction, reinforcing the manufacturer’s reputation for reliability and serviceability.