Case Studies

Application: Ultra high volume metal stampings needed "just-in-time"

Challenge: One of Res Manufacturing Company's customers requires up to three truckloads of parts (approximately 170,000 units) per week on a "just-in-time" basis. Like many of our customers, this company operates in highly competitive domestic and foreign markets. They hold only three days of inventory and rely on Res to supply components on time while helping to find ways to reduce costs.

Outcome: Since the relationship began, Res has saved this customer more than 30 percent. Because the parts are high in material content, there are not many opportunities to reduce the unit cost. Res reviewed the production process and supply chain and recommended alternatives in materials, a redesign of several parts, and a change to returnable containers. Each of these changes resulted in dramatic cost savings for the customer.

Application: Moving existing tooling from a non-performing metal stamping supplier.

Challenge: The customer had sourced the part with another supplier and was experiencing problems with excess lubricant and poor part quality. They were concerned about the supplier's ability to perform as they ramped up to full production.

Outcome: Res associates developed a project plan to ensure the smooth transfer of the tooling, while meeting production requirements. Res engineers proposed a tool modification that eliminated the need for additional lubricant and improved the formed features of the stamping. In order to meet the customer's price objectives and delivery schedule, a cross-functional team of Res associates developed an elaborate part ejection chute system to speed up the manufacturing process. Res production associates also came up with a new method for stacking the stampings in returnable containers, resulting in safer transport and lower freight costs.

Application: Outstanding outsourcing to alleviate the customer's manufacturing capacity constraints.

Challenge: The customer was producing a stamping in-house and due to capacity constraints, on-time delivery and sales were suffering. Impressed with Res' advanced capabilities and experience with high carbon materials, the customer gave Res a call. The real challenge was whether Res could produce the part at or below the customer's in-house costs.

Outcome: Res' ability to process heavy gauge metal from coil (up to .500") and very competitive sources for raw material enabled us to meet the customer's cost requirements.

The move to Res freed-up capacity for the customer, allowing them to ship orders on-time and increase their overall response time with little capital expense. This customer was amazed with Res' ability to purchase exceptional quality raw materials at competitive prices and is now using our supplier for their other raw material needs.