Process Improvement

Continuous improvement of manufacturing processes leads to nearly 50% cost reduction on wireless network diplexer components.

Top / Bottom Diplexer Set


Our customer, a leader wireless telecommunications OEM required reducing the costs of its diplexer product line in order to maintain its competitiveness.


Working collaboratively with the customer to improve product design and manufacturing processes, in combination with manufacturing increased efficiencies resulted in substantial cost reduction.  A continuous process improvement program yielded the following achievements:

  • Developed an imaginative and orderly tombstone fixture design which allowed for rapid load/unload while increasing batch efficiency and reducing component set-ups required from 3 to 1.
    • Improvement resulted in 7.9% cost reduction.
  • Established inspection protocol utilizing a multi-part simultaneous set-up which allowed for meticulous 100% first article inspection with no negative impact on plant production efficiency.
    • Improvement resulted in 1.2% cost reduction.
  • Replaced the standard rectangular material blanks with a streamlined and low-waste alternative as a result of designing a pair of custom aluminum extrusions.
    • Improvement resulted in 5.5% cost reduction. More tightly controlled tolerances allowed for further streamlining of the pair of custom aluminum extrusions during a time when commodity market pricing was high.
    • Improvement resulted in 0.9% cost reduction.
  • Increased set-up efficiency, reduced inventories, and simplified process for production personnel by standardizing tooling libraries across part number and band derivatives
    • Improvement resulted in 5.1% cost reduction.
  • Dramatic efficiency improvements were realized, as a result of investing in a cutting-edge CNC milling machine capable of very high speed tool changes and rapid rates with maximum spindle speeds of 15,000 RPM’s.
    • Improvement resulted in 6.7% cost reduction.
  • Design changes were implemented for 3 features as a result of collaborative work customer and engineering staff to analyze the expected cost savings of an array of potential design changes.
    • Improvement resulted in 6.7% cost reduction.
  • Programmers continually shaved seconds from CNC programs by maximizing feed rates, optimizing choice of tool, minimizing tool path lengths, and establishing smart program home positions.
    • Improvement resulted in 4.8% cost reduction.
  • Implemented additional design changes to provide for faster post machining assembly and tuning.
    • Improvement resulted in 1.3% cost reduction.
  • Realized economies of scale by maximizing the utilization of production hours through strategic diversification of products
    • Improvement resulted in 1.8% cost reduction.
  • Significantly reduced cycle times and WIP inventories, while maximizing work-center utilization. Modeling a variety of scheduling and production floor scenarios using sophisticated ExtendSim software provided a vehicle for analyzing toggled variables in virtual reality.
    • Improvement resulted in 3.4% cost reduction.
  • Further minimized average required set-up time, by working with simulation data to develop real-world what-if scenarios that targeted the most efficient production grouping possibilities
    • Improvement resulted in 1.0% cost reduction.


A series of noteworthy improvements from our experienced manufacturing professionals resulted in a component cost reduction of nearly 50% over a period of three years. Continuous process improvement at Olympic Precision Machining resulted in increased efficiency and reduced costs, thus guaranteeing product competitiveness.