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Sometimes the client comes with a ready-made vision. He has the parts, the idea and often also the belief that he knows best what will work. But it is precisely in such moments that the value of experience and team approach is manifested. This was also the case — a seemingly simple project turned into an interesting example of how a good technological analysis can pay off a solution that is more effective, durable and better suited to the needs of the user.
Customer with own material - with drum and tubes
A customer came to our office with an unusual order. He brought a drum and a set of tubes for bending. He wanted us to make heaters for him from the tubes provided — so that they fit the drum. As it turned out later, it was a heater for a device of a kind of industrial pancake maker. The problem was that we had not implemented such a project before. Even the pricing of the service itself proved difficult — the heater was to be made unusually, from material supplied by the customer and matched to a specific device.
A total change of concept
Not a tubular heater, but a ceramic one
The first concept was to make a tubular heater — the customer was convinced that it was the best solution. In the original device, there were as many as six tubular heaters, wrapped in a spiral. The customer assumed that he would use the same solutions — and the supplied tubes were to be used as a base for the new heating elements.
However, after consultations within our team — including the production leader, technologist, sales manager and head of the company — we came to a different conclusion. An alternative was invented: instead of six tubular heaters, create one ceramic heater in a metal casing, which will perform the same functions, and even do it better.
[space for photo: team analyzing the project]
One heater instead of six — less is more
The proposed solution required not only a change in technology, but also a reformulation of the customer's approach to the whole concept. However, it turned out that a well-justified proposal falls on fertile ground — the client accepted the new idea, both technically and financially.
The ceramic heater we created not only replaced six smaller heaters, but also proved to be a more durable and energy efficient solution. Due to proper adjustment of parameters, adaptation of the design to the specifics of the device and the use of materials with higher durability, it was possible to increase the service life of the heating element without degrading the quality of work.
[place for photo: finished ceramic heater in a metal casing]
End result: more durability, fewer complications
In the end, we completed a project that was more than just the execution of the order — was an example of cooperation, openness to analysis and flexibility in thinking. The customer received a functional and durable solution that not only simplified the design of the device, but also increased its reliability.
This example shows that it is worth looking at the design more broadly — not always what was used before is the best solution for today. Thanks to the experience of our team and the courage to propose new ideas, we managed to design a heater that works better, longer and more economically.