Performance

Process Improvements

Developed and Implemented "Autogrinder" machine to remove flash from butt-welding operation

• 80% reduction of manual grinding process
• 50% productivity increase

Regression Model utilized to optimize CNC production program for roll bending operation

• 15% productivity increase
• 300 labor hours reduced annually

Insourced 80 production tool-sets from closing facility and improved process for internal machinery

• $10 million in savings after 2nd year
• $90 million savings in 10-year project life

Design

Over 10 component parts redesigned to reduce machining material plus stock

• $575,000 savings in first year of implementation
• YTD savings of $7.48 million

Researched and implemented new material for production tooling

• 3.4x die life for only 2x tool cost

Tooling Standardization

Overhauled product tooling with new features and standardized sub-components related to machinery available in-house

Changed materials used to increase life of sub-components

• $700,000 savings in first year of implementation
• YTD savings of $2.45 million

Equipment Implementation

Replaced existing production saw with high performance machine. Prevented massive cost incurrence having foresight of future product orders that were beyond current machine capabilities.

• $3.6 million in costs avoided in first year
• YTD savings of $14.4 million