Mar 2025 – Apr 2025
What?
Led the redesign of a coil finishing process to support high-volume production of bent wires for a large manufacturing order
How?
- Evaluated existing 90-degree wire bending methods and identified scalability limitations
- Reviewed the full coil finishing workflow with engineering and production teams
- Proposed an omega-shaped wire bend to enable faster forming, finishing, and cutting
- Designed and built a press-style jig inspired by cookie-cutter manufacturing
- Conducted cost and material waste analysis to validate production viability
Result
- Enabled efficient production of 20,000+ units with improved ergonomics and throughput
- Reduced coil finishing time from 5 minutes to 3 minutes per unit
- Eliminated the primary production bottleneck in a process unchanged for over 15 years
Nolan Phuong 