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.


Res associates developed a project plan to ensure a smooth tooling transfer, 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.

THE FINAL OUTCOME: Safer transport and lower freight costs