From concept to serial production
Development and production of a sustainable brass product range
In this case study, we provide a detailed account of how a complex development and manufacturing project in the field of lead-free brass processing was realized. The focus was on the successful implementation of a new product line in the sanitary sector that complied with strict legal requirements and met high quality standards.
Background & initial Situation
The customer, an established supplier of high-quality sanitary systems, planned to develop an innovative series of connectors consisting of both plastic and metal components. The aim was to launch a new, innovative series of connectors that would be particularly durable and reliable and would represent a technological advance in the market.
In terms of the materials selected, the series had to comply with current and future legal requirements, particularly with regard to lead-free content (in accordance with the Drinking Water Ordinance and REACH).
The challenge was to develop the new range in such a way that it could be manufactured in a technically and economically viable manner. This involved taking into account different manufacturing techniques and material properties to ensure that the products could be produced cost-effectively without compromising on quality. In addition, extremely tight tolerances and a special surface finish were required, which made the manufacturing process and handling even more difficult.
Project start
Right from the start of the project, it became clear that intensive communication between the customer and our development team would be necessary. Cooperation began early on in the development phase, which made it possible to incorporate design and material-related aspects into the process at an early stage.
First, our team received drawings of the planned components from the customer, which we subjected to a comprehensive feasibility analysis. In this early phase, our technicians identified a number of points where design adjustments were necessary. For example, it was suggested that certain wall thicknesses be reduced or threads shortened in order to make production more efficient and economical, but without compromising the durability and reliability of the product. We were also able to provide advice on the choice of materials, drawing on our many years of experience with lead-free brass alloys such as CW724R (“Ecobrass”). The customer, who had previously focused on traditional red brass alloys, recognized the long-term advantages of this more sustainable, lead-free alternative.
Prototype development
During the development phase, we produced initial prototypes and test samples to check the functionality, service life, and approval status of the connectors. Throughout this process, there was continuous, constructive communication between the two project teams so that they could respond quickly and flexibly to any challenges that arose.
After successful testing of the prototypes and finalization of the material selection, the implementation phase began. A joint project team was assembled, which held regular coordination meetings via video conference. Transparency and clear communication played a central role, especially given the tight deadlines and complex tasks.
Production planning
Production preparation included machine selection, batch size determination, calculation of manufacturing costs, creation of test plans in quality assurance, and preparation of initial sample test reports. Since assembly was also implemented in this case, the preparation also included commissioning assembly systems and planning the assembly process. Due to the high requirements for precision and surface quality, it was necessary to use specialized tools, some of which required longer lead times to procure. At the same time, the necessary material was procured, which was specially selected for this application.
Selection of material
When selecting the material, the alloy was chosen specifically for the connector series. However, we always check which raw material—round bar, hollow bar, or solid bar—is best suited to the respective item and the required quantity. Hollow and SW rods are more expensive to purchase, but due to lower machining requirements, they allow for a faster machining process and reduce the amount of chips produced. This results in a more efficient use of materials. In addition, the outer diameter of round and hollow rods is optimized as far as possible to the final dimension. When using hollow bars, the largest possible inner diameter is selected, whereby design eccentricity limits must be observed. Especially for small batch sizes, a round bar can be more economical than a hollow bar.
Serial production
Based on the determined quantity and cost data, the manufacturing costs were calculated and comprehensive test plans were drawn up as part of quality assurance. Initial sample test reports were prepared to document the conformity and functionality of the components. Since assembly work was also carried out in this project, the appropriate assembly equipment for O-ring and press body assembly was commissioned and the assembly process was planned in detail.
Series production began with a detailed initial sampling of a total of around 200 different brass items. After a certain start-up period, several initial samples with corresponding test reports were sent to the customer on a weekly basis, who also checked the samples. The process was intensive and time-consuming, as components with particularly tight tolerances required individual treatment and inspection. Due to the high requirements, certain components, for example, had to be plugged in individually and cleaned gently, which required greater logistical and personnel effort.
Results
In the end, despite all the challenges and temporary bottlenecks, the product line was completed two months ahead of the planned market launch. The manufactured components met the strict specifications regarding quality and material conformity with future legal requirements.
A key outcome of the collaboration was the realization that early joint development work offers considerable advantages. Early exchange not only enabled production costs to be optimized, but also ensured that unexpected problems could be identified and eliminated at an early stage.
The greatest challenges
Various challenges arose during the course of the project, requiring the project management team to respond flexibly and quickly. For example, there were delays in the delivery of special tools and assembly equipment that had not been originally planned for. In addition, there were temporary bottlenecks in material procurement and delays caused by external suppliers.
The project team also had to coordinate the effects of the coronavirus pandemic, absences due to illness, and bottlenecks during vacation periods. The most important lesson learned here was that forward planning and transparent communication are essential in order to meet deadlines despite such difficulties.
CustomerFirst-Approach
This project once again highlighted what defines BEULCO's service philosophy: speed, commitment, and absolute reliability. When the customer had a particularly urgent need, we responded flexibly and with a focus on finding a solution—even on the weekend. Our employees voluntarily worked extra shifts so that no time would be lost.
Regular communication with the customer was a matter of course for us – this enabled us to respond to current requirements at any time and offer optimal solutions. For us, partnership means more than just delivering a product: we stand by our customers – even when the going gets tough.
Lessons Learned
For future projects, it became clear that sufficient time buffers should be planned in order to cope with unexpected challenges such as tool and material availability. It is also advisable to build up a more generous stock in advance of the market launch in order to further reduce risks in terms of delivery capability.