Custom Solution Provides Efficiencies

Custom Solution Provides Efficiencies

Tanning Bed OEM Outsources Harness Manufacturing

Challenge

A tanning equipment, supply and service company sought an outsourced contract manufacturing to partner with to efficiently and timely produce an industrial tanning bed

Solution

  • Design, engineer, and implement a total custom manufacturing solution
  • Create customized assembly protocol and time-efficient production
  • Successfully produce, store and deliver final cost-effective product for testing and end-use delivery

Results

  • A customized production schedule was developed, allowing for a timely delivery of product that was cost effective
  • Streamlined processes and cross-trained production staff to optimize assembly production ultimately providing quick production turn-around times
  • Successful manufacturing collaboration resulting in a continuation of an ongoing working relationship

Download the complete case study.

Wholesaler Chooses to Outsource

Wholesaler Chooses to Outsource

Wine and Beer Home-Brewing Wholesaler Outsources Manufacturing

BlichmannChallenge

Securing an outsourced contract manufacturing to partner with to efficiently and timely produce an electronic control box for an electronic brewing system

Solution

  • Accept initial prototype, reverse engineer, secure materials, produce and package an electronic control device as an all-encompassing custom manufacturing solution
  • Utilize cross-trained skill sets as a complete manufacturing partner to streamline assembly protocol and time-efficient production
  • Successfully design, produce, package and deliver final cost-effective product for customer use

Results

  • Using an initial prototype and employing reverse engineering developed a customized, cross-trained production system
  • Streamlined production and cross-trained production staff to optimize assembly production ultimately providing quick production turnaround times
  • Successful manufacturing collaboration resulting in a continuation of an ongoing working relationship

Download the complete case study.

Inventory Levels Decreased

Inventory Levels Decreased

Case Study: Outsource Strategy for $5B OEM

Situation

A $5B manufacturer of mail processing equipment was using over 750 unique cable assemblies throughout their equipment product lines.  In engaging ALTEX, the OEM’s objective was to outsource sub-assembly work in order to focus on their core competency of design and final assembly.  The OEM also experienced high inventory cost and quality issues.

Solution

The ALTEX engineering and manufacturing team developed a dedicated work cell that could handle the customer’s low order quantities and the large number of different assemblies. Working closely with the customer, the ALTEX team transitioned production of the entire cable package over a 6-month period  with minimal interruption.

Result

The ALTEX team successfully implemented an outsourcing strategy for this OEM. The customer achieved lower inventory levels while improving product quality and availability.  ALTEX became an extension of the customer’s manufacturing process and contributed to improved time-to-market performance.

Design Prevents Field Failure

Design Prevents Field Failure

Case Study: Security Systems Manufacturer

Situation

A Fortune 500 security systems company experienced ongoing field failures of communications cable used in an automated door access system in a high-traffic, highly secure environment. ALTEX was challenged to design a solution that would prevent this failure.

Solution

ALTEX’s product and manufacturing engineers worked very closely with the client to design a flexible cable harness assembly that could withstand the number of flexes expected over the security product’s lifetime. A connector system was sourced to meet the application’s low current requirements.

Result

The new design went through extensive life-cycle testing and successfully was implemented into the security product. ALTEX was awarded the production business to build the new cable assembly.

Re-Engineering Improves Function

Re-Engineering Improves Function

Case Study: Product Re-Engineered to Improve Functionality

Challenge
A leading process monitoring equipment company asked ALTEX to redesign an existing product.  The design objectives were to reduce product size and to increase its networking capability.The product is used in a factory floor environment where vibration and RF interference exists.

Solution
ALTEX’s engineering team worked closely with the customer’s engineering group to define the key parameters for the product and began their work on a new design. The enclosure size and orientation of the connectors were a critical consideration. After creating the new design, ALTEX’s product engineering team worked with their strategic supply base to source an enclosure that met the size requirements and had good RF characteristics.  The original flex cable was changed to a printed circuit board solution that eliminated the need for hand soldering and improved reliability in the manufacturing process. A returnable shipping program was established with the printed circuit board supplier to reduce packaging costs and eliminate any transportation related quality issues.  The connectors used in the product were redesigned to a product offered by one of ALTEX’s distribution lines. This lowered the raw material costs and improved the supply chain support.

Result
This project had been on the customer’s “wish list” for over a year.  ALTEX’s efforts moved the project to a production phase and accomplished the original design objectives of reduced size and improved networking capabilities. The program is currently produced at ALTEX’s Westfield, Indiana manufacturing plant.