Customer Case Studies : Process Improvement Solutions

Impact of our Solutions

  • Stock & Release Programs Save Time & Money
  • Provide High Quality Cut-to-Length and Slit Coils
  • ISO 9001:2008 Certified
  • Problem Solvers
  • On-time Delivery
  • Quick Responsiveness

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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
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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
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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" - 4") 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
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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)
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