About Agility Fuel Systems

Agility Fuel Systems is the leading designer and producer of alternative

fuel storage and delivery systems for heavy duty trucks, buses and
specialty vehicles.
The result of two industry-leading companies, Agility combines FABs
world-class expertise in compressed natural gas and liquid natural gas
fuel storage systems with Enviromechs industry-leading engineering
talent in alternative fuel vehicles.
Business Challenges
A company with expertise in creating alternative fuel systems
had plenty of mechanical engineering skill, but they needed EMS
expertise. Their new electronic controller for a natural gas fuel system
was expensive to produce and took too long to manufacture.
The sub-optimal safety control module design required unique
expertise to fx and this frm needed an EMS provider with enough
breadth and depth of experience to solve the problem.
If forced to use multiple vendors to source the necessary components,
the production lead times would be too long. The customer base
demanded the new controller. A solution was required and a partner
was found.
ControlTek had the expertise to improve the product design and
analyze the production requirements, then swiftly deliver on those
requirements. They knew how to make the safety control module
better than its original design. Better. Cheaper. Faster.
Solutions
ControlTek immediately identifed ways to solve problems with the electronic controller, and then executed on
those solutions using a cooperative multi-disciplined process.
Design Improvement
Engineers at ControlTek worked to improve the design, resulting in reduced cost drivers and a streamlined
manufacturing process. By changing the design concept, the need for machining was eliminated. ControlTek
specifed a custom plastic injection mold enclosure that saved money over the original of the shelf concept.
Agility Fuel Systems - Building Your Product Better, Faster, and Cheaper
Electronic Manufacturing
Services Provider
Background
Since 1996, FAB has been the
leading supplier of compressed
natural gas (CNG) and fuel storage
systems to leading transit bus
OEMs and heavy truck feets.
Founded in 2001, Enviromech
is an engineering-driven
manufacturing company serving
the alternative fuel industry.
Working together for more than
a decade, these two companies
have engineered an impressive
range of fuel system solutions.
Cable harnessing eliminated the need for fying connectors, thus
rendering the controller less cumbersome. The ability to deliver a new
design and a documented prototype diferentiated ControlTek from
many of its competitors lacking the capability to do so.
Rapid Execution
Facing a tight schedule, ControlTek quickly produced prototypes to
prove the design concept. Calling on years of experience and depth
of expertise, ControlTek personnel worked closely with the client to
determine the optimal manufacturing requirements.
The collaboration resulted in additional design input before
transitioning to the production phase of the custom cable assemblies
and creation of a test system. All of this was accomplished during
production rollout in a short time frame.
Supporting JIT Manufacturing
ControlTek designed the supply chain to support Just In Time (JIT)
deliveries. With a toolbox thirty years in the making, ControlTek
was able to tailor a supply chain solution that met the electronic
controllers delivery requirements. The supply chain strategy for the
electronic controller included leveraging purchasing power, sourcing
for replacements of obsolete or scarce components, and deploying
Lean Manufacturing techniques to improve efciency.
Results
Better. Cheaper. Faster. The electronic controller was once a
headache. With the help of ControlTek it is now a competitive
diferentiator. Each week full unit orders now ship directly from
ControlTek to customers.
Realizing Success
With ControlTek as a single source provider for the electronic
controller, the client beneftted from:
A More Durable Product The plastic injection molded
enclosure ensured reliability in harsh conditions.
Streamlined Product - Replacing the fying connectors
created a more elegant design and a more efcient product.
Change to connectors is real streamline.
JIT Deliveries Supply Chain Design improved efciency and
reduced risk.
Reduced Costs Original unit production cost was $110.
Now it is $59.
ControlTek helped turn a crisis management situation into an
opportunity for product and production improvements their client
didnt think were possible.
Agilty Fuel Systems
www.agilityfuelsystems.com
3905 NE 112th Avenue Vancouver, Washington 98682
TF: (866) 818 - 9855 | Vancouver: (360) 896 - 9375 | Portland: (503) 242 - 3526
www.controltek.com
The Results
The partnership with ControlTek
resulted in:
A more durable product
engineered for reliability under
harsh conditions.
A streamlined product that
included more elegant design
and a more efcient product.
Improved efciency and
reduced risk in Agilitys supply
chain.
Reduced unit costs from $110
to $59.