Problem:

ComAp was supporting a new large engine for their customer to replace an older model serving the oil and gas industry, with a projected lifecycle of 7–9 years. They needed a reliable set of harnesses for the prototype and eventual production models. However, the initial design for the harness was complex and difficult to manufacture efficiently.

Solution:

Our team collaborated closely with ComAp during the prototype phase. We reviewed the available prints, held multiple design conversations, and built the initial prototype according to their specifications. Recognizing the inefficiencies in the build process, our team dedicated a weekend to creating an alternative prototype. This revised design maintained all necessary functionality and fit but significantly simplified manufacturing.

Result:

When both versions were presented to the customer, they chose our simplified alternative. This decision allowed them to reduce overall production costs and streamline the harness assembly process. While the new engine is still undergoing regulatory approval and has not yet entered the market due to unrelated compliance issues, our harness design met all requirements and remains unaffected by the delay.