Case Studies

Precision Steel Casting - Key component as part of an agricultural plough

Project Objective

To reduce component weight, reduce individual part inventory, reduce part handling and labour to manufacture culminating in significant cost reduction.

Project Method

GMS assisted with the design in converting the component from a multipart fabricated and machined assembly to a one piece precision finished machined steel casting. This individual component has enabled the customer to reduce inventory, deploy the required labour with other tasks, reduce component weight at the same time improve performance. In addition a 30% part cost saving was achieved.



Precision Metal pressing - Mining machinery bulk handling conveyor bearing housing

Project Objective

To improve the lifetime, durability against fatigue fracture and performance of this key element of the conveyor.

Project Method

GMS were engaged to facilitate design changes that would achieve the project objectives. By utilising the latest tooling technology we were able to produce a bearing housing profile that was lighter in weight, more robust and durable in performance which in practice has assisted in greatly reducing the power requirements needed to drive the conveyor. By reducing the component weight we have also achieved a 29% cost reduction with 50% increased lifetime of the bearing.



Fabrication and assembly - Fin and Plate construction of an air cooler for a turbo system used on commercial vehicles

Project Objective

Reduce the power consumption of the cooling system to reduce fuel costs, lower emissions and improve system efficiency.

Project Method

GMS were invited to assist in the design for manufacture of this application. Through thorough evaluation of air flow based on material form and shape the final production product which is a precision formed and fabricated assembly, has achieved power consumption reductions in excess of 90%. This has the direct effect of reduced fuel usage and significantly lower emissions.