- Pump Components
Simplifying a Complex Flange Assembly for Texas Pump OEM
Frigate partnered with a North America–focused Pump OEM to streamline the production of critical flange assemblies. By introducing closed-die forging with precision machining, Frigate eliminated multi-step fabrication, reduced lead time, and ensured tariff-free delivery—all while guaranteeing perfect fit and strength.
- 40% faster production achieved with optimized forging process
- 30% cost savings compared to conventional fabrication + welding
- 100% fit accuracy validated through interlocking design tests
- Zero tariff impact with shipment delivered before April 9 deadline
Category
Closed-Die Forged Pump Components
Industry
Industrial Pumps – Agriculture & Dewatering
Core Capabilities
Value Engineering, Forging, Precision Machining, Design Validation, QC & Supply Chain Agility
Complex Manufacturing Process
The client was using a combination of fabrication, welding, and machining to produce flanges. This multi-step process increased production time, raised costs, and weakened structural integrity.
Inaccurate Drawings
Initial drawings provided by the client had dimension mismatches, which created delays during the validation stage and risked production rework.
Tariff Deadline Pressure
New US import tariffs were scheduled for April 9. The client needed the complete order shipped before this cutoff to avoid significant duty charges.
- Operational Risks
Customer Key Challenges
The project required simplifying a complex flange assembly, reducing manufacturing time and costs, and ensuring tariff-free delivery within strict deadlines.
- Execution Results
Key Highlights
Frigate streamlined the client’s complex flange assembly production by adopting forging-led value engineering, ensuring faster turnaround, cost reduction, and tariff-free delivery.
- Strategic Actions
Key Solutions
Frigate implemented value engineering, rapid validation, and supply chain agility to simplify the flange assembly, reduce costs, and ensure on-time tariff-free delivery.
Requirement Analysis
Reviewed client’s flange assembly drawings, identified mismatched dimensions, and assessed bottlenecks in fabrication, welding, and machining processes.
Design & Engineering
Created a new 3D model with corrected specifications, defined interlocking fit standards, and prepared manufacturable drawings for forging and machining.
Prototyping & Validation
Executed First Article Inspection (FAI), conducted dimensional and interlocking fit tests, and secured rapid client approval to proceed without delays.
Production Setup & Execution
Implemented closed-die forging + precision machining, optimized operations from five steps to two, and ensured daily QC tracking across batches.
Quality Assurance & Delivery
Carried out stage-wise inspections, validated dimensional accuracy, and delivered final shipment, avoiding new tariff impacts.
- Delivery Excellence
Execution Process
Frigate drove the project from requirement assessment to final shipment through a structured, precision-driven workflow ensuring speed, quality, and tariff-free delivery.
Outcomes of the Client
- Cost Savings – Achieved ~30% reduction in overall part cost by shifting to closed-die forging instead of fabrication + welding.
- Faster Lead Times – Delivered components 40% faster, meeting urgent project timelines.
- Quality Accuracy – Achieved 100% dimensional fit with validated interlocking design, eliminating rework.
- Tariff-Free Delivery – Shipment completed on April 8, avoiding heavy import duties.
- Improved Strength – Forged parts provided superior structural reliability compared to welded assemblies.
- Client Appreciation – The OEM’s Head of Business personally thanked Frigate for saving both time and cost.
Client Testimonial
“Excellent news. Thanks again for everything and please pass our very warm thanks to all who have made this possible. Frigate’s ability to simplify a complex process, correct design issues, and still deliver before the tariff deadline saved us both cost and time.” — Head of Business, Texas Pump OEM
About Frigate
Frigate specializes in high-precision engineering and advanced manufacturing solutions. By combining design validation, prototyping, multi-vendor integration, and quality assurance, Frigate enables global companies to localize production, achieve cost efficiency, and ensure scalability.
Ready to Build with Frigate?
Partner with Frigate for high-precision, high-performance manufacturing solutions. From prototype to full-scale production, Frigate delivers quality components on time and at scale.
- Real Impact
Words from Clients
See how global OEMs and sourcing heads describe their experience with our scalable execution.
“Quick turnaround and solid quality.”
“The instant quote tool saved us time, and the parts were spot-on. Highly recommend Frigate!”
“I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and take their ideas to manufacturing. One firm doing all kinds of Product Development!”
“Great service, fair price, and the parts worked perfectly in our assembly.”
“Top-notch machining and fast shipping. Very satisfied with the results.”
“The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way! I personally believe the Frigate's way of IIOT enabled cloud platform with Al.”
“Frigate delivered high-quality parts at a competitive price. The instant quote tool is a huge plus for us!”
“We appreciate the precision and quality of the machined components in the recent delivery—they meet our specifications perfectly and demonstrate Frigate’s capability for excellent workmanship.”
“Flawless execution from quote to delivery.”
“I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.”
“The precision on these parts is impressive, and they arrived ahead of schedule. Frigate’s process really stands out!”
“Parts were exactly as spec’d, and the instant quote made budgeting a breeze.”
“Good value for the money.”
“The finish was perfect, and the team was easy to work with.”
“Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.”
"We are highly satisfied with the timely delivery and quality of the MIG Welding Cable from Frigate. Their attention to detail, secure packaging, and quick responsiveness stood out. We confidently recommend Frigate Engineering Services Pvt. Ltd. as a reliable manufacturing partner."
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