Customer Case Study:
Process Improvement Solutions

Major Hand Tools Manufacturer

Before Our Solution:

• Customer handling multiple runs of slit and edged steel (1/2” x 0.125”) coil in 100 lb. size due to customer’s machinery and process limitation
• 40,000 lb. Run took 1 month at 2 shifts or 320 hours

Our Solution:

• We studied our customer’s process carefully
• We suggested they use Siegal Strip Oscillate Wound (edge plus oscillate process combination) to produce a continuous welded coil of 3,000 lbs.
• 40,000 lb. run now takes 2 weeks with no incremental coil handling labor
• Saved 240 hours of machine time

Customer Impact:

• Revenue upside:
• 200% savings in machine uptime created huge revenue upside for customer
• Man-hours savings in coil handling is now applied to revenue generating tasks
• Better competitive position:
• With 200% lower time usage to process the 40,000 lb. job, customer’s profitability and competitive position for that job was dramatically improved

Major Specialized Industrial Doors Manufacturer

Before Our Solution:

• As demand for low-cost non-rusting convention doors shifted towards larger panels, customer could no longer use standard galvanized steel panels due to flatness issues

Our Solution:

• We carefully investigated the customer’s problem
• We suggested using cold-rolled steel panels with a special acrylic coating with long-lasting adhesion properties that provided rust protection without compromising flatness
• We produced sample product for our customer to evaluate

Customer Impact:

• Our customer adopted our suggestion and was able to meet the demands of their customers without losing market share
• Our customer was able to deliver an improved product to their customers, with far superior price/performance characteristics

Major Window Hardware Manufacturer

Before Our Solution:

• Our customer was regularly suffering rejection of entire shipped window hardware orders by its window manufacturer customer due to surface irregularities that caused window production failures

Our Solution:

• We carefully investigated the customer's problem and concluded that their entire value chain was being compromised by the source of the original steel
• Our customer had been purchasing strip steel from a supplier who was in turn purchasing steel coil from a mini-mill to minimize cost. This supplier did not understand the special requirements of strip steel to meet the stringent surface quality needs of window hardware 
• We showed the customer that the problem arose from the fact that mini-mills started their cold- rolled production from thin slab (3/8") rather than the thick slab (7/8") used at the integrated mills. This fundamental difference is a crucial factor in surface quality of thinner strip coil.

Customer Impact:

• Our customer recognized steel sourced by us from integrated mills and processed to meet the surface quality needs of window hardware, was essential to meet the needs of their end-market
• Switching to steel from integrated mills costs our customer slightly more, but they have never had a surface quality problem after adopting our recommended solution and have further improved their competitive position with their window manufacturer customers

Major Tier Two Automotive Stamper

Before Our Solution:

• Customer used nearby warehouse to store up two months of raw material inventory
• Inventory turns and cash flow suffered

Our Solution:

• Set up "just in time" program for over 50 items
• We ship daily and make customer changes with hours

Customer Impact:

• Inventory hold went from 60 days to 2 days
• Cash went up
• Quality actually improved during transition (See our chart)