Case Study 3: High-Volume Consumer Product

Component Application: The "Cap Strap" by Tahr Equipment is a consumer product used in multi-pitch rock climbing, whitewater kayaking, and other outdoor activities. It is constructed of powder-coated aluminum and a webbing strap to create a strong connection point for Nalgene water bottles.

Customer Problem: In the summer of 2022, Griffin Marshall, co-founder of Tahr Equipment, successfully whitewater kayaked the Grand Canyon. He returned with a unique product idea in the form of a rough prototype used to secure a Nalgene to rafts and packs while on the water. However, Tahr Equipment needed a trusted partner to handle engineering, manufacturing, and supply chain logistics to get the product from an initial concept to a finished product.

LHM Solution: Our involvement with Tahr Equipment showcases our entire suite of manufacturing services, bringing the Cap Strap product from the brainstorming stage to a high-volume consumer product with a robust US-based manufacturing supply chain:

• Engineering and Design for Manufacturing Services: At LHM, we are experts in CAD and 3D modeling. We can help take a concept to a finished design or help refine your existing design for improved manufacturability. We modeled and iterated on the Cap Strap design, factoring in user feedback, manufacturability, and durability test results.

• Prototyping: Through the stages of the design process, we produced prototypes using both rapid 3D printing to check component fit and CNC machined aluminum prototypes to test the product's durability. We then worked with local vendors to quickly produce samples using production processes before committing to larger orders.

• Supply Chain Management: At LHM, we have significant production capabilities for mid to high-volume component manufacturing. However, our core competency is CNC machining of complex components, a relatively expensive manufacturing process compared to other industrial manufacturing methods.

  
  
  
  

  When involved with design and DFM consulting work, we can steer our customers in a design direction that results in economic and scalable manufacturing. In the case of the Cap Strap, the best choice was to utilize high-volume sheet metal and industrial sewing vendors to produce products domestically at a competitive price.

  
  
  
  

  Through a rigorous process, we evaluated vendors based on several factors, including quality, price, delivery, and scalability. Based on these evaluations, we developed a 2-tier supply chain with a primary and secondary supplier for every critical operation in the manufacturing process. This system offers redundancy to Tahr Equipment's supply chain to ensure that production is independent of a single point of failure.

• Packaging Design: Optimizing every step of the process is critical to making consumer products in the US. Performing time studies, we were able to redesign retail packaging to reduce packing labor by 80%. Often, an increase in efficiency requires a significant upfront investment in automation or equipment. However, in this case, we made simple changes that reduced labor times and eliminated carpal tunnel-type motions without substantial upfront investment.

• Production Management, Quality Control, and Assembly: Today, LHM continues to manage all vendors throughout the manufacturing process. The product is then received at LHM's facility, where it can be quality-controlled, packaged, and distributed to wholesale accounts and 3PL facilities. Utilizing LHM for final assembly, quality control, and packaging, Tahr Equipment can eliminate the need for its own warehouse to store in-process products. Tahr can also rely on us to monitor vendors' ongoing quality and performance, ensuring a quality process and product.

In the spring of 2023, LHM Engineering formed an official partnership with Griffin, and we are now proud to be a co-owner, taking an active management role in Tahr Equipment's day-to-day operations. Seeing the brand's massive growth in DTC and retail environments has been inspiring, and we are excited about the future of building in-house products to complement our suite of manufacturing services.