Problem
A Fortune 500 renewable-energy company faced significant manufacturing delays and cost overruns due to design inconsistencies, incorrect tolerances, and assembly-sheet inaccuracies in their offshore wind-turbine systems. The client required a comprehensive design audit to identify risks, correct documentation, and streamline global engineering workflows.
Approach
As the mechanical engineering specialist on the Bain case team, I conducted a detailed review of CAD assemblies and technical drawings using Siemens NX. I applied GD&T principles to verify fit, tolerance stack-ups, and manufacturability. Working with engineering teams in India and France, I mapped design discrepancies, standardized correction protocols, and coordinated cross-border workflows to ensure alignment and traceability.
Solution
I validated and updated more than 150 sub-assemblies, correcting drawing errors, resolving mismatched tolerances, and ensuring each component adhered to manufacturability and documentation standards. I established a clear workflow for design corrections, enabling distributed teams to identify issues quickly and update models without disrupting the original design intent.
Impact
The audit uncovered design anomalies that translated into ~$200M in potential cost savings for the client by preventing manufacturing defects and operational failures. The streamlined workflow and corrected documentation reduced projected engineering and production delays by ~1000 hours, improving cross-team efficiency and accelerating the client’s development cycle.