P.O. Box 98
4000 Rives Eaton Rd
Rives Jct, MI 49277 p: 517.569.3380
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Throwing Away Money? A Case Study for Cost of Quality Rework Reduction
Customer was experiencing alarming inefficiencies on the assembly line due to reworking a small diameter wire form product supplied by another supplier.
A potential customer was experiencing alarming inefficiencies on the assembly line due to reworking a small diameter wire form product supplied by one of our competitors. The part didn’t fit the weld fixture consistently due to part complexity and wire size. Struggling with its current supplier’s multiple ineffective Corrective Action Reports, unanswered phone calls and emails, and after thousands of dollars wasted on reworking and expedited shipping expenses they had finally endured enough loss.
Rives Manufacturing Incorporated has assembled a staff of experienced engineers with the skill sets that cover a vast range of expertise. A robust knowledge of automated processes, tool design, mechanical engineering, metallurgy, problem solving, and general business processes are what made it possible for RMI to propose an alternative process and tooling design. This ingenuity would eliminate the costly reworking the customer was currently enduring.
Understanding machine capabilities and limitations along with complimentary tooling designed around such small wire diameter, RMI was able to manufacture the component in one operation and eliminate the rework all together. The solution was splitting it into two parts to eliminate the variation while using the original assembly fixture.
We earned a new customer by helping solve a painful cost of quality. Our new customer recouped the tooling costs within the first month of production due to their increased rate of production realized by eliminating the rework without incurring additional processing costs.