Oshkosh Truck

Problem/Challenge Low Volume Production
Oshkosh Truck the premiere manufacturer of class 7&8 trucks for the US Military was faced with a catastrophic situation. The Patriot Missile vehicles were built with an auxiliary battery that was catching fire (literally) as the trucks were being driven onto the transport ship bound for the Middle East. Oshkosh’s engineering staff designed a new grounded cover that would eliminate the fire hazard. Timing was critical, Oshkosh needed 4000 covers in two weeks.

Solutions/Results Rapid Tooling
Oshkosh came to General Pattern with this important time sensitive situation. General Pattern’s tool design staff worked with Oshkosh engineering staff to design a part that met or exceeded the specifications that was moldable in the timeframe needed. General Pattern’s 24/7 approach to tool making and the application of our newly developed KBM (knowledge based machining), executed the large injection mold (12 x 18 x 12) with multiple side actions in less than 10 days and first parts in 13 days.

Benefit/Impact Low Volume Production
In 2 weeks Oshkosh Truck made field retrofits that eventually would tally 4000 units. The trucks are now in operation protecting our safety… “and the caissons keep rolling along!!!”

Commercial
Tool Price $30,000
Unit Price $2.50
Performance Tools completed in 2 weeks