When a leading escalator manufacturer sought to cut costs without compromising safety or quality, they turned to Goken for support through Value Analysis/Value Engineering (VAVE) and Should Costing methodologies. The goal was to reduce the overall cost of the escalator by at least 10% across multiple modules, while preserving durability and performance
The Challenge
Escalators are complex assemblies, consisting of several modules such as the truss, handrail system, step band, skirting, landing, and both upper and lower modules. Each component contributes to safety and reliability, but also to overall cost. The challenge lay in identifying opportunities for cost savings that would not affect compliance with industry standards or passenger safety.
Traditional approaches to cost cutting such as reducing material quality or simplifying parts would have undermined the escalator’s structural integrity. Instead, the client needed an engineering-led solution that optimized design, material selection, and part standardization.
Goken’s Approach
Goken’s team began with a deep analysis of the truss structure,
Goken’s Approach
Goken’s team began with a deep analysis of the truss structure, one of the most critical and cost-intensive elements of an escalator. Using advanced CAE (Computer-Aided Engineering) simulations, they re-optimized the truss design to reduce weight while maintaining strength. This involved replacing traditional square cross-sections with lighter L- and C-shaped channels and strategically applying high-strength steel only in areas of higher stress. The revised design provided modularity for future product lines, while delivering a 5.5% reduction in weight and cost.
Beyond the truss, Goken targeted other key modules for value engineering:
- Material Substitution: By replacing aluminum and stainless steel with galvanized steel in non-critical areas such as the upper and lower modules, decking, and step band, costs were reduced by 5.8%. Since these parts were less exposed to corrosion, the substitution delivered significant savings without added risk.
- Bracket Optimization: High-cost brackets were redesigned to reduce unnecessary surface area while maintaining the same performance, delivering a 1.3% cost saving verified through CAE.
- Part Standardization: Where different parts had previously been used for left and right sides, Goken proposed using a single standardized part with slight modifications. For example, by adding one additional hole, the same component could be applied on both sides. This reduced the number of SKUs and simplified manufacturing, saving another 3.1%.
- Handrail Adjustments: The width of handrails was modified to match industry standards, resulting in a modest but meaningful 1.1% cost saving.
- Thickness Reduction: Several parts had been designed with excess material thickness due to supplier limitations. By reducing thickness in low-stress areas, sourcing flexibility improved while costs fell by an additional 4.2%.
The Results
Through a combination of design optimization, material substitution, and SKU rationalization, Goken developed a comprehensive cost-reduction strategy. What began as a 10% minimum savings target was far exceeded by a total proposed cost reduction over 25%.
This delivered immediate financial benefits for the client and streamlined their manufacturing process, reduced part complexity, and opened opportunities for future modular escalator designs.
Conclusion
The escalator cost reduction project illustrates how VAVE and Should Costing go beyond traditional cost cutting. By applying smart engineering, advanced simulations, and a deep understanding of component performance, Goken helped the client achieve significant savings without compromising safety, strength, or reliability.
