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Our customer needed a new turnkey supplier for a molded roller assembly consisting of a hub, rubber overmold, and hardware. To reach their target part cost, they had to buy components at scale, and they were struggling to manage every...
We partnered with three of our principals to deliver a complete, finished assembly. Our team established estimated annual usage (EAU) and inventory min/max levels, which supported a blanket order that let the customer buy at scale and at a price point that worked for them. Releases are then shipped just-in-time to match their build schedule.
A custom machine builder needed a precision plastic guide, approximately 2.6 m x 1.5 m, to merge eight assembly lines into a single channel for packaging. Because the components and timing were so exacting, the guide had to hold tight...
Newact machined the entire part in a single setup, holding tolerance from end to end. Their precision routers cut the guide channels, then changed tools mid-run to add countersinks and mounting holes. Other shops would typically machine one half, remove and reorient the part, then machine the other half, which risks the very tolerances the guide depends on.
The customer was experiencing supply and quality disruption as the business was scaling to meet demand. The customer worked with Clow on how their unique manufacturing process can scale quickly to meet their delivery and quantity demand.
Our team analyzed their unique process to combine stamping processes in fewer actions. By incorporating blanking, piercing and stenciling into one tool, incorporating coil feeding and one additional forming process, we were able to meet their pricing and delivery requirements. Our value-added network provided the additional plating required allowing Clow to provide the customer with a finished part.
Our client in the recreational industry requires a bracket on a 10,000 part blanket order. The former laser and bend price on 2,500 pieces was $2.65, with no additional tooling charges.
Using our proven process, at a 2,500 piece release, each part cost approx. $1.45 (with a one-time $1,000 tooling charge). By switching to short run stampings, our client generated an $11,000 savings (on 10,000 pieces annually). If you had 10 parts like this, you could generate over $110,000 a year in savings.