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