When our team was manufacturing in-store ordering kiosks for a global quick-service restaurant, one key requirement of the project was making the product design easy for employees to swap out the receipt paper when needed. 

But we didn’t want those same employees to access the high-voltage internal components and risk damaging the units (or themselves). With that in mind, we designed the kiosks with two separate compartments:

1. 1. One that allowed easy access to the printer
2. 2. And another that remained securely locked and was only accessible to trained technicians 

This is just one example of how thoughtful design decisions can make a product easier and safer to service. These decisions, which fall under the broader category of serviceability, are an important and often overlooked part of the design process. That’s why, at Nu-Way Industries, we make it a priority on every project we take on. Our extensive experience with outdoor enclosures, kiosks, and complex integrated cabinet systems gives us a practical, real-world lens for designing products that perform well not just on day one but every day thereafter.

This experience forms the backbone of our product design services, which prioritize serviceability, usability, and real-world applications from the start.  

What Is Product Serviceability?

Product serviceability refers to how easily a product can be accessed, maintained, or repaired over its life. It includes everything from changing filters and replacing components to dealing with environmental damage or user misuse. 

While it may seem like a “nice-to-have” feature, serviceability is just as important as material selection or aesthetics. In our experience, ignoring it often leads to higher labor costs, more frequent failures, and frustrated end users. 

How Early Questions Lead to Better Designs

When presented with a new development project, we could provide a quote, no questions asked, and if ordered, pass it straight to our manufacturing engineering team. And while that is how many contract manufacturers work, that’s not how we do things at Nu-Way Industries. 

Rather than simply following a set of instructions, we begin by stepping back and getting a full, bird’s-eye view of the product and its intended use. This process may feel like a game of 20 questions, but it’s an essential part of how we approach our product design services, setting every project up for good serviceability from the very beginning. To that end, we ask questions like: 

• – What is the product’s function? 
• – Where will it be used?
• – Who will interact with it?
• – How will it be installed or accessed?

This discovery process recently helped us guide a prospective customer in the right direction. They came to us because they wanted to discuss a rooftop enclosure for propane fuel cells and voltage inverters they were developing, and assumed it needed to be fully NEMA-rated. However, after getting a better understanding of the application, we realized that a NEMA rating wasn’t actually necessary. 

Instead, we recommended a more straightforward solution: a secure, modular enclosure that will protect the components and can be assembled easily on-site, eliminating the need for a complicated or expensive installation process.

We also considered real-world servicing conditions: what happens when a technician is on a rooftop in freezing wind (or blazing heat) and drops a screw in the gravel or snow? To help avoid this likely scenario, we recommended using removable panels secured with captive fasteners that stay attached during service. It’s a small detail that will make a big difference when working in the field. 

This level of questioning revealed opportunities we wouldn’t have uncovered otherwise, and guided design choices that will make rooftop installation simpler, allowing for easier serviceability in the future. 

3 Reasons to Think About Serviceability Early

When serviceability is prioritized early, it enhances the user experience and yields a higher-quality product. Here are a few of the key benefits we consistently see: 

1. 1. Reduced Long-Term Costs: Design decisions that reduce or eliminate service cycles directly lower operating costs. For example, we helped a customer redesign their outdoor signs for passive convection cooling, eliminating the need for fans and filters—two components that typically require ongoing maintenance, but experience showed that maintenance is seldom carried out.
2. 2. Longer Product Life: When a kiosk or cabinet is easy to access, routine maintenance is more likely to occur. This kind of accessibility supports predictable upkeep and helps extend the product’s lifespan.
3. 3. Improved Usability and Safety: As the restaurant kiosk example illustrates, different users should have different access levels. Creating physical barriers or keyed access to sensitive components protects the safety of the user and the equipment.

Product Design Factors That Make or Break Serviceability

From hard-to-reach access panels to overengineered (and costly) features that no one uses, there are several common mistakes that compromise the serviceability of the product. During the discovery and design review process, which are built into our product design services, we consider factors such as: 

• – Accessibility: Are doors, panels, and components easy to access when needed? Does the design include captive fasteners to prevent dropped screws during rooftop or outdoor servicing?
• – Human Interaction: Does the design limit pinch points or exposure to electrical components? Does it include angled tops or crowned surfaces to prevent users from setting drinks (or worse) on the product? 
• – Environmental Considerations: Does the design account for the environment in which the product will ultimately be used? For example, a kiosk in a busy train station must be built for durability and abuse, while a rooftop enclosure must endure weather extremes and rough handling by service technicians.

In short, it’s wise to assume that people will misuse things; designs should reflect this simple fact of life. That principle is central to our work at Nu-Way Industries. With decades of experience and tens of thousands of product interactions behind us, we’ve seen it all. That history helps us spot issues early and make informed, practical recommendations that lead to better results.

Bring Serviceability Into the Conversation Early

Having a conversation with your manufacturing partner about the user experience and serviceability of your next product is an essential step in the design process. Not only can it save money and reduce failures, but it can also improve usability from day one. 

Whether you’re still in the concept phase or you have an initial drawing in hand, our engineering team would love to talk with your team. The sooner you integrate serviceability into the design process, the fewer costly surprises you’ll face later, and the better experience you’ll deliver to your end users and service teams. 

Our product design services are rooted in practical insight and backed by decades of contract manufacturing experience. Reach out to our team and request a quote today.

Manufacturing is a business that’s all about the details, and as a contract manufacturer partner, the more we know and the sooner we know, the better the end result for all involved.

But how early should you start discussing your needs with your manufacturing partner?

The answer to that is — it depends. But with a bit of information as to the why behind lead times, you’ll quickly realize the benefits of getting your manufacturing partner involved earlier rather than later and when it’s essential that you do so.

At Nu-Way Industries, we have over 50 years of experience in sheet metal fabrication. We know what it takes to manufacture high-quality products for our customers and deliver on time every time. Whether you’re looking for a sheet metal fabrication partner for a new product or need volume production of your existing parts, Nu-Way Industries can provide you with the quality contract manufacturing services you need. 

Mitigating the Risks of the Unknown

Aside from open capacity and industry-wide supply chain disruptions, lead times are principally driven by the risk of the unknown; in other words, what challenges we might encounter during manufacturing. While that may sound a bit nebulous, it’s really quite simple and based on two key things: familiarity and complexity.

Familiarity: New Parts vs. Reorders

When we say familiarity, what we mean is whether we’ve manufactured a specific part or product for you before. When manufacturing something for the first time, there’s often a degree of uncertainty involved in what it takes to get the job done correctly — and sometimes, this can take a bit of extra work, as well as a bit more time.

Orders for New Parts & Products

As a rule of thumb, when you come to us with a new part or assembly for us to produce, we generally require 6 – 8 weeks of lead time to get your order on our production schedule and guarantee the best results. Additionally, the better your documentation and the more detailed your specifications, the easier it will be for us to understand your needs.

To further reduce the risk of any issues that may impact quality or lead time, if you come to us just a little earlier — even a week or two — we’ll be able to more thoroughly discuss your designs with you, perform any required manufacturability engineering, and get all the necessary approvals to ensure that everything arrives to you on schedule.

Repeat Orders for Parts & Products

As a contract manufacturing partner, things become more efficient the more we work together, and orders of parts and products we’ve manufactured before are naturally more streamlined. Since we’re already familiar with your part designs and specifications, so long as we don’t need to account for any design modifications, all we have to do is fit your order into our production schedule. 

It’s that simple.

While lead times can vary depending on our open capacity, we’ll always provide you with clear communication so you’ll know when exactly your parts will be completed, shipped, and delivered.

Complexity: Simple Parts vs. Complex Parts

Whether a part is simple or complex can depend on various factors, but in sheet metal fabrication, it largely depends on your part or product’s design, application, and the features it needs to have.

Simple Parts & Products

Simple parts are just that: simple. As such, they have fewer variables to consider in terms of manufacturability. This makes them inherently low-risk, with few potential unknowns, and we can manufacture these types of parts quickly, accurately, and efficiently.

Complex Parts & Assemblies

Complex parts are typically more challenging, and there’s a higher risk of encountering unknowns during manufacturing. These might include manufacturability issues that require redesign, sourcing hard-to-find purchased items in the BOM, or any other issues that could arise due to the nuances of your part or product.

But regardless of what’s driving complexity, these types of parts require more study, planning, and care in execution to mitigate the risks of the unknown. This is a multidisciplinary effort that requires frequent, meaningful, and accurate communication within our team and also between your team and ours. With regular open communication and detailed specifications, we can ensure that when it comes to manufacturing your complex parts and products, nothing is left to chance. 

It’s Never Too Early to Get Your Contract Manufacturing Partner Involved

While identifying all potential issues that may arise during manufacturing is nearly impossible, working with an experienced contract manufacturing partner can reduce the risk. At Nu-Way, we have an impressive range of in-house capabilities spanning all facets of precision metal fabrication and sheet metal finishing. By having all of this in-house, we can quickly and efficiently address any issues that may arise, ensuring a smooth manufacturing process from start to finish.

With decades of experience providing sheet metal fabrication services, we’ve worked with customers to manufacture parts and products of all complexities and volumes, and have delivered exceptional results every time. If you’re seeking a contract manufacturing partner that can provide you with a streamlined service for your manufacturing needs, reach out to our team and request a quote today.