Case Studies

Case Study 1 - Castings

Description

  • Gravity castings for a guttering business produced in-house by tooling coming to the end of its useful life

Opportunity

  • High material cost due to thick wall sections has produced a high component cost, further accentuated by high labour costs to de-flash, finish and rework rejects

Solution

  • Redesign to injection casting and resource to Asia

Outcome

  • Material cost was reduced by circa 50%
  • Process capability improved thereby reducing in-process rejects caused by porosity and short shots
  • Improved product integrity and strength
  • Reduced labour cost for manual operations
  • Retooled at significantly lower cost than could be achieved in-house
  • IRR less than 1 year on capital repayment

Case Study 2 - Mouldings

Description

  • New product opportunity to introduce a range of complex thermoplastic injection mouldings, constrained by limited capital investment funds

Opportunity

  • To produce an extensive range of customer bespoke moulded fittings to simplify a customised and high cost manual assembly operation.  The supply of these mouldings is to provide a competitive advantage USP associated with a high-value associated product that is core to the customer’s business

Solution

  • Source from Asia

Outcome

  • Low cost tooling
  • Low production costs
  • Smaller batch quantities
  • Consolidated shipping to achieve low logistics cost

Case Study 3 - Aluminium Extrusion

Description

  • To reduce the cost of and improve the quality of a range of high value added premium finish products

Opportunity

  • Previous supply chain was fragmented between different suppliers and prone to quality deficiencies caused by material handling

Solution

  • Resource to a vertically integrated low cost manufacturer

Outcome

  • Reduced material handling damage
  • Reduced non-value added secondary packaging
  • Reduced double handling premium
  • Increased process ownership and quality performance
  • Reduced cost