PROBLEMS WE SOLVE
Engineering is most valuable when it changes the outcome.
These examples show how OMI has approached customer problems across motors, gearing, welding equipment, fluid systems and precision manufacturing—starting with the operating challenge and engineering a practical route to production.
CUSTOM STARTER MOTORS & BENDIX
Polaris Industries
Long-term custom engineering for demanding vehicle applications
2007relationship began
5K–170Kmotors / year
1M+Bendix units
01 / CUSTOMER CHALLENGESince 2007, OMI has supported Polaris vehicle programs requiring custom starter-motor and Bendix solutions across widely varying annual volumes. The applications have presented challenges including extreme temperatures, vibration, durability and tight packaging constraints.
02 / OMI ENGINEERING RESPONSEOMI designed and manufactured application-specific starter motors and Bendix systems, modifying materials, grease and assembly processes where required to address heat in moving components and improve suitability for the operating environment.
03 / PRODUCTION RESULTPrograms have ranged from approximately 5,000 to 170,000 starter motors per year, with more than one million Bendix units supplied across the relationship.
ADDITIONAL CASE STUDIES
Different industries. The same engineering discipline.
MANUFACTURING PROCESS REDESIGN
Thermadyne
Reducing drill-bit failures while cutting tooling cost
CHALLENGEThermadyne was drilling holes in solid copper welding nozzles with expensive drill bits that could jam, break and cause both the tool and the copper nozzle to be scrapped.
OMI RESPONSEOMI redesigned the drill profile to remove copper shavings more rapidly, reducing heat and breakage, and changed the manufacturing process used to produce the drill bit.
RESULTThe redesigned manufacturing process reduced drill-bit cost by 70% while improving drilling durability.
70%drill-bit cost reduction
DFM / PROCESS IMPROVEMENT
MECO Regulators
Lower-cost components with improved finish and easier assembly
CHALLENGEMECO required improvements to the manufacture of components used in its high-pressure regulators.
OMI RESPONSEOMI introduced different manufacturing methods focused on component cost, product finish and assembly efficiency.
RESULTComponent cost was reduced by 30%, while product finish and ease of assembly were improved.
CUSTOM REVERSE MOTOR
Harley-Davidson
Engineering a more durable reverse-drive solution for a trike application
CHALLENGEThe existing reverse motor used on the trike had significant failures that were causing customer dissatisfaction.
OMI RESPONSEOMI designed the traction motor and electronics to be waterproof, engineered the pinion to release when the vehicle moved forward, and increased motor torque and durability.
RESULTThe redesign addressed the identified failure modes through a purpose-built reverse-motor system engineered around the vehicle application.
PACKAGING & DRIVETRAIN DESIGN
Weber Automotive / Arctic Cat
A different starter architecture for snowmobile packaging
CHALLENGEThe application required an alternative to the traditional offset Bendix and starter arrangement.
OMI RESPONSEOMI designed an inline motor and planetary Bendix architecture for the snowmobile application.
RESULTThe resulting architecture provided a purpose-designed alternative to the conventional offset layout.
NEW PRODUCT DEVELOPMENT
Continental Emsco
Expanding a competitive product range with engineered fluid modules
CHALLENGEContinental Emsco wanted to broaden its offering with additional competitive products for mud-pump applications.
OMI RESPONSEOMI was contracted to design and manufacture fluid modules used in mud pumps.
RESULTThe program supported a broader product range prior to Continental Emsco being acquired by National Oilwell.
PRODUCT DEVELOPMENT
Thermadyne
A cost-competitive welding kit for entry-level and DIY customers
CHALLENGEThermadyne wanted a welding-kit offering suited to entry-level welders and DIY users.
OMI RESPONSEOMI designed and manufactured a cost-competitive welding kit for the target market.
RESULTThe project created a dedicated product offering aimed at entry-level and DIY customers.
DESIGN FOR MANUFACTURE
Confidential Welding Company
Using DFM to support an expanded TIG welding product offering
CHALLENGEA welding company wanted to expand its product range with a TIG welding kit.
OMI RESPONSEOMI designed the TIG welding kit for manufacture around the customer’s product-expansion objective.
RESULTThe customer gained an engineered path to broaden its welding-product offering.
Customer name confidential.
YOUR APPLICATIONBring OMI the problem, not a finished specification.
We can start with the operating challenge, identify the disciplines required and determine the most practical route from concept through manufacturing.
DISCUSS YOUR ENGINEERING CHALLENGE →
