Case Study:
Engineering Cost Savings

Situation: A Tier 1 auto supplier was sending a family of stabilizer bar blanks to one supplier for cutting and then transporting them to another supplier to machine both ends.

Solution: We saw opportunity for the customer to save on both manufacturing and transportation costs.  Our innovative design of custom handling and feeding equipment ran both ends automatically in a CNC machine cell, resulting in significant savings. We also reduced transportation needs by performing the cutting and machining in one facility.

Result:  We saved our customer over 50% on their machining and transportation costs, totaling several million dollars over the life of the contract. 

Case Study:
Problem Solving

Situation: A customer came to us with a problem:  Bar mill tolerance made it difficult if not impossible to assure the specified weight tolerance on a forging blank. The customer was considering peeling the material to get closer tolerances, facilitate saw cutting, and enable cutting to weight. 

Solution: We devised inspection and engineering processes to avoid this extra cost and still maintain highly capable quality processes for their cut-to-weight parts. In addition, our review of their part lengths enabled us to recommend more optimized bar lengths from the mill.

Result:  The customer avoided millions in extra costs, while improving quality and lowering yield losses.

Case Study:
Customer Service

Situation: A manufacturer of axle shafts called at 4:00pm on Wednesday with an emergency schedule change—it was the day before Thanksgiving. 

Solution:  We understand the industry and that a production line must be supplied and cannot be shut down because a part isn’t there.  Our management team stayed late and unloaded the material, still warm from the mill, Wednesday at midnight.  After Thanksgiving dinner, we ran the parts, and delivered them ahead of schedule, leaving our trailer for our customer to unload at their convenience.