CUSTOM CAP NUT REDESIGN DELIVERS +$346,000 IN ANNUAL SAVINGS
A customer’s exterior assembly was secured using six custom cap nuts with a specialized plating. While the existing design met the required 500 hours of red rust salt spray resistance, it was a high-cost component with a history of supply chain challenges.
As part of a VAVE cost savings supplier event, the customer identified the cap nut as a priority opportunity and challenged Field to develop a lower-cost alternative without sacrificing performance or durability.
Leveraging Field’s fastener manufacturing and engineering expertise, the team redesigned the custom cap nut to create a more cost-effective solution.
The new design can be cold formed using fewer manufacturing processes than the existing component while maintaining the required form, fit, and function. Field also specified a zinc-nickel finish capable of withstanding 500 hours of red rust salt spray testing, ensuring the alternative continued to meet the customer’s demanding environmental requirements.
The proposed redesigned custom cap nut will provide the customer with an estimated $346,000 in annual cost savings, representing a reduction of more than 39% compared with the existing design.
Beyond the significant cost reduction, the project demonstrates how Field can combine VAVE, engineering, sourcing, and fastener manufacturing expertise to simplify component designs, address supply chain challenges, and deliver measurable value—without compromising performance requirements.
TOTAL SAVINGS:
$346,281.90