Driving Cost Savings and Reliability for Medical Sink Assembly

The Challenge: Reduce Cost and Eliminate Weld Failures

DeWys Stainless Solutions was approached with an existing sink assembly used in medical applications.

While the product was functional, it presented two key challenges:

• Field weld failures, impacting reliability and customer confidence
• Opportunities for cost reduction, particularly through minimizing welding operations

The goal was clear: improve manufacturability, reduce welding where possible, and maintain the high standards required for medical environments. The medical customer also brought forward design ideas aimed at making the product more cost effective.

The DeWys Solution: Design for Manufacturability

Our engineering and production teams worked closely with the customer to evaluate the existing design and identify opportunities for improvement.

The primary focus was to redesign the assembly to minimize post-welding operations.

By rethinking part geometry and fabrication methods, we were able to:

• Reduce the number of welds required
• Simplify the overall assembly process
• Improve structural integrity through smarter design rather than added weld material

This approach not only addressed the weld failure issue but also streamlined production, creating a more efficient and repeatable manufacturing process.

Implementation: From Concept to Completed Sink

After finalizing the redesigned concept, our team moved into production with careful attention to quality and consistency.

Key implementation steps included:

• Engineering validation of the updated design
• Process adjustments to reduce welding touchpoints
• Controlled fabrication and finishing to meet medical-grade standards
• Quality checks to ensure long-term durability

The result was a completed medical sink assembly that met all functional requirements while significantly improving manufacturability.

Results: Lower Cost, Higher Confidence

The impact of the redesign was immediate and measurable:

• Lower production costs due to reduced welding and streamlined fabrication
• Zero weld failures in the updated design
• Improved bottom-line performance for the customer
• Increased customer satisfaction and confidence in the product’s reliability

By minimizing weld-dependent features and optimizing the design for efficient manufacturing, we helped our customer turn a challenge into a competitive advantage.