Case Studies

Challenge During an assembly line review with a potential customer, the Field team noticed that a considerable amount of meter boxes were being scrapped and removed each day. Upon further review of the assembly process, the team observed that the workers were having problems with tapped thread quality and recess damage.

Challenge During an internal lean audit at Field, a team member was reviewing the frequency of transactions associated with a small group of fasteners being used by one customer. The team member discovered the number of transactions was inconsistent with the value of the product. The customer was managing a Kanban program internally and was shipping low dollar items on a regular basis and ...

RETHINKING THE ROLE OF SUPPLIER TECHNICAL SUPPORT  Challenge The Field Engineering team provides hundreds of line reviews, product tear downs, and other technical support services every year to identify cost savings for our customers. The challenge is getting the cost savings implemented because fastener/ fastening issues are generally a low priority.

Observations and Solutions During a technical line review of a customer’s facility, the Field team observed the components and methods of manufacturing used to assemble an engine. The following observations were made with corresponding solutions:

CROSS FUNCTIONAL TECHNICAL TRAINING BENEFITS CUSTOMER WITH A TOTAL SAVINGS OF $73,193 Observation and Solution Upon reviewing a customer’s request for a quote for new parts, a Field account manager discovered several parts being ordered had a special plating request. The plating requested was a high end organic finish that would provide a great resistance to corrosion, but would require multiple ...

FIELD REDESIGN AND PROCUREMENT YIELDED $32,700 IN TOTAL SAVINGS  Challenge The Field team initiated an engineering review of a customer’s product that revealed a problem they were having with a specific part. The machined part was subject to occasional cracking, due to the notch-sensitive nature of parts produced by the screw machining process. Part dimensions needed to be largely maintained due ...

Challenge Field’s customer was facing strong cost pressures as the only domestic manufacturer of their electronic products. Based on recommendations from Field on similar products, the large number of brass inserts and machine screws were targeted for evaluation. The current injection molded parts were designed with 32 brass inserts in thread sizes from 2-56 up to 6-32.

Challenge During a plant Gemba Walk with a current customer, Field observed an assembly condition and took steps to perform an Applications Problem Solving and Assembly Line Review of their manufacturing process when applying tape to pipe plugs and pipe nipples.

OVERHAUL OF CLIENT'S VMI PROGRAM YIELDS COST SAVINGS OF $50,000 Challenge Looking to improve on-time delivery, and reduce customer involvement and time needed to manage their hardware VMI program, a prospective customer elected to engage in discussions with Field. Inefficiencies with on-site scanning and replenishment, and overall organization of the program were weak. This led to parts hoarding ...

PART REDESIGN AND PROCURMENT IMPROVEMENT YIELDS TOTAL SAVINGS OF $206,500 Challenge During a technical line review of a customer’s facility, the Field team worked with the director of purchasing to identify cost-reduction opportunities among high-volume parts. One element in particular drew their attention: a stainless steel window hardware part.

FIELD INITIATED ENGINEERING REVIEW AND PRODUCT REDESIGN YIELDS $170,000 IN COST SAVINGS Challenge Field initiated an engineering review of a customer’s application that revealed a high-cost component, which required multiple assembly steps and created potential quality concerns. Field provided engineering resources to redesign a more cost-effective part that lowered component costs, assembly ...

FIELD EXECUTED A SEAMLESS TRANSITION AND REDUCED PROCUREMENT TIME BY 90% Challenge A manufacturer of signaling devices had a muddled VMI system in place that had excessive inventory levels yet daily stock outs. The supplier had a 8,000 sq/ft in-plant store onsite that was taking up valuable production floor space. The damage included 1,500 part numbers in over 5,000 bins and 55 VMI stocking ...