Custom Battery Pack Solution to Reduce Labor Costs
Challenge
Epec approached a manufacturer of motion hunting solutions, knowing that they used batteries for one of their products and we asked them what their battery solution was currently. They were buying a battery from China, modifying it to add a custom cable modification to match their motor and charger connections, and putting the battery in an enclosure and potting it.
Being a multiple-engineered product manufacturer, Epec reviewed the actual cables they were using and determined we could customize the cables with custom overmolded connectors to solve that manual labor problem that he was having. So, we designed a battery to meet the same battery requirements and performance that he was currently getting but with a custom cable and connector already on it.
The supporting charger they were using required them to do the same thing; buying an off-the-shelf charger. They were modifying the cable by splicing it with a custom connector. So, we took that project on to create a custom cable with a custom overmolded connector that would match with the battery.
Solution
Through the development process, we had to build samples and ship them to the customer for approval. They had to pot them and test them in the field. We simplified his process by taking the manual labor out of it by customizing both the battery, the battery cables and connectors, and the charger by creating the custom cables and overmolded connectors.
They didn't understand we had the capability to customize what they had been purchasing off the shelf and having to modify themselves. Our sales team presented our capabilities to later have several in-depth conversations about other products and applications we have customized to save customers time and costs. Epec could potentially provide a solution to manage the whole process to customize it and take out the purchasing and in-house assembling steps they were currently managing.
This customer is a small business and was skeptical because they didn't understand what their current costs were and how this would all streamline the process and go to their bottom line. After working with them on quotes and logistics and having them research their actual costs, the customer saw an advantage to what Epec was proposing. They then had to invest in an upfront NRE for us to tool up the custom over molds needed for the cabling and we began. We sampled these customized products including the battery with custom cable and connector, the charger with custom cable and connectors, and an extension cable they later added to the products with the same style of custom overmolded connectors.
The solution we provided was to eliminate all the manual labor steps that they were currently doing, which was tedious and time-consuming; they didn't have any idea of their costs and labor because they were never faced with comparing it to other available options.
Result
Our solutions were more robust and more streamlined, so the quality was drastically improved, and it helped them by reducing their manual labor steps for both products (battery and charger). The customer received the battery, charger, and extension cables in the final use design without doing the internal modifications. Epec also simplified their ordering process by being the sole supplier for all three products they need, and by being able to manage scheduled releases to them so they can reduce their inventory costs.
Want to Cut Costs on Your Custom Battery Pack?
Epec’s expert engineering team specializes in designing and producing cost-effective, production-ready custom battery packs for your application. Let us help you streamline your design and manufacturing process to save money without compromising performance. Reach out today to get started!
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