Case Study I – Machined Aluminum Castings

After producing their aluminum castings for more than 30 years, our customer informed us that new ownership dictated that in-house machining would be discontinued and that all castings would be purchased fully machined.  We reached an agreement with the customer to purchase the portion of their machinery that related to our castings.  The agreement included machining programs and fixtures.  We also needed to adapt one of our existing buildings to accommodate the new cells.  The transition occurred over twelve months as finished stock was built in the customer’s inventory and raw casting stock built in ours.  Throughout the process, scheduled conference call meetings and in-house training sessions were conducted.  In the end, the transfer of the machinery, first article approval, and production shipments were made without production stoppage.    

Case Study II – Machined Brass Castings

Growth in a customer’s business created a situation where they needed to either add to their internal machining capability or look for machining support.  We had been producing their castings for many years but had never done any of the machining.  The pump related brass castings fit nicely into our turning cell arrangement and the transition was successful.  We continue to machine the parts today.  The customer has improved their inventory turn and has been able to concentrate their resources on other facets of their business.

Case Study III – Offshore Castings and Assembly

A manufacturing company with their own captive aluminum foundry came to us after years of frustration with the foundry’s negative impact on the overall operation of their business.  They wanted to close the foundry and concentrate their resources on their product line.  This meant they needed a supplier capable of delivering all of their castings completely machined.  Their tooling was quite old and in constant need of maintenance.  They were an ideal candidate for our facility in China.  We knew that we could reproduce all of the tooling economically and deliver their machined castings at a cost which would allow them to amortizing the tooling very quickly.  Our involvement has now grown to include not only castings but also stampings and assemblies.

Case Study IV – Product Design

A customer was purchasing an off-the-shelf product as part of their OEM system.  They were unhappy with the performance of the purchased product and felt that it was limiting their market potential.  They came to us with a scenario that involved the design of a new component that tripled the performance of the existing product yet put it in a smaller and lighter package.  We developed a three phase approach that included technical feasibility, product design/development, and finally the tooling and production of the product.  The project was tasked to our design team in India.  Using some components known to be available and some newly designed structural parts, we developed and simulation tested a new product that exceeded their performance criteria while staying within the size-weight package allowed.  The product specifications were finalized in Phase II.  In Phase III, the component drawings and assembly drawings were finalized so that full production could begin.