Nuts and Bolts: Examples of Our Work
Case Study: Coordination
When a major automotive supplier was looking to reduce its supplier base, they turned to Fasco for a different approach. The company had been purchasing a "blank" from one manufacturer, and then had to manage four other suppliers to get the product completed. As the product criss-crossed the USA for each step, it became a logistical nightmare for the customer to manage.
Using reverse engineering, Fasco identified each of the individual process steps required to make this product. We worked within the current Fasco supply chain to simplify each step in the process. Ultimately, we concluded that by rearranging the process flow and suggesting a new subcontrator, operational steps could be combined, lead time could be cut in half, and cost reduced by 30 percent. The customer liked our suggestion.
Company executives wanted to know how many suppliers would have to be engaged for this project.
The answer? Just one. Fasco.
Case Study: Plating
A hardware manufacturer presented us with a "colorful" situation.
In their business, product appearance is essential to quality.
This customer plated their primary products in-house, with over 20 different finishes. Their previous fastener supplier imported plated fasteners, but these often didn’t match the finish of the hardware. End users were calling the customer’s 1-800 complaint line demanding return authorization--a big quality problem!
Fasco worked closely with the customer and our local plating suppliers. We developed a process that would provide a match for the required appearance. The designated range was acceptable to the customer and within the supplier’s capability. A good "match"!
Case Study: Improving the Design
A major automotive supplier was experiencing quality problems with a part in an important sub-assembly. The part was initially machined from bar, followed by several secondary operations performed by multiple suppliers.
Over time, the assembly began to perform at a less than desirable level. This seemed to indicate that a possible redesign of the assembly would be necessary.
Fasco became involved at the engineering level and
proposed recommendations to convert the primary process to
cold heading.
The inherent strength properties of this process are superior to the old design.
Fasco prototypes enabled the customer to better focus their redesign effort. Fasco was also able to eliminate all but one secondary operation, which simplified the part.
The result is an improved assembly, achieved along with cost savings. With Fasco coordinating the complete effort through its supply chain, it also enabled the customer to focus efforts elsewhere, and reduce its supply base.