• Consolidated 2 welding cells to 1

• ~2× throughput improvement (cycle time reduction)

• ~$100K/year labour savings

• $8K tooling cost reduction

• Eliminated redundant part handling steps

• Two identical parts processed in separate weld cells

• Mirror parts required separate setups and changeovers

• Cycle time bottleneck limited plant optimization

• Needed reuse of existing tooling + minimal downtime

• Redesigned tooling for dual-orientation part compatibility

• Added secondary lower electrode without weld interference

• Introduced pneumatic actuation for tooling repositioning

• Converted full copper plate to localized copper inserts in aluminum base

• Maintained compatibility with existing weld infrastructure

Production-focused mechanical design under strict cost, downtime, and manufacturability constraints. Delivered measurable throughput and cost improvements through tooling and process consolidation.