Customer Challenge

Our customer was sourcing a linkage/selector arm assembly from an international metal stamping manufacturer but faced significant quality issues. The parts were not meeting dimensional criteria, and the problem was worsened by inventory delays due to shipping. These issues caused production delays and increased costs, impacting the customer’s overall operational efficiency

Reshoring to WI-based Metal Stamping Manufacturer HTT Nets Solution

HTT’s engineering team collaborated closely with the customer’s engineering team. They conducted a thorough evaluation of the parts and identified the failure mode. The solution involved a process change and retooling of the parts. Specifically, they introduced a solid boss in the welded assembly and added a post-weld machining step.

Results

This process change allowed for superior dimensional control of the features and datum structures, effectively resolving the customer’s pain points. The parts now met the customer’s dimensional criteria, eliminating the quality issues experienced with the previous metal stamping manufacturer. As a result, the customer experienced:

  • Improved Product Quality: The parts met all dimensional specifications, ensuring reliable performance.
  • Reduced Lead Times: By sourcing to a local metal stamping manufacturer, the customer reduced inventory delays and improved supply chain efficiency.
  • Cost Savings: The reduction in quality issues and inventory delays led to significant cost savings.

Lessons Learned

  • Design for Manufacturability: Early engagement with customers in the design process can prevent issues and optimize part performance.
  • Collaboration: Close collaboration between engineering teams is crucial for identifying and solving complex problems.
  • Process Innovation: Adapting and innovating manufacturing processes can lead to significant improvements in product quality and reliability.
  • Local Sourcing Benefits: Sourcing locally can mitigate risks associated with international supply chains, such as delays and quality issues.

This case underscores the importance of end-to-end customer solutions and the value of a metal stamping manufacturer working closely with customers to address and solve their unique challenges. By leveraging its engineering expertise and innovative processes, HTT was able to deliver a solution that not only met but exceeded the customer’s expectations.

HTT specializes in high volume end-to-end supply of services for metal stamped components and assemblies.  We simplify the supply chain and utilize upfront design consultation to streamline manufacturing requirements. Our approach ensures high quality, on-time delivery, and optimizes costs. As a result, our customers can save time, realize best-value pricing, and gain a reliable partner.