Case Study: Alacriant's Rapid Rescue Team Revitalizing Agriculture OEM Production
Alacriant’s Rapid Rescue Team is committed to swiftly addressing critical challenges in manufacturing, ensuring minimal downtime and optimal production. This case study highlights our recent intervention with a leading Agriculture OEM facing line-down implications due to a troubled offshore supplier.
Problem Statement
The customer experienced a line down situation
caused by an offshore supplier struggling to
deliver conforming parts. The initial request was
for 2,500 pieces as a one-time order to supplement
the incumbent, with a critical need for PPAP
completion in less than four weeks. The urgency
included building weld fixtures and reaching a
production rate of 100 pieces per day post-PPAP
approval.
Objectives
- Addressing: Promptly addressing the line-down situation is crucial for Alacriant.
- Timeline: Alacriant aims to achieve PPAP approval within a tight 4-week timeframe.
- Approval: Establishing a production rate of 100 pieces per day post-PPAP approval is a priority for Alacriant.
Outcomes
The implementation of our methodology resulted
in the following outcomes:
Swift Response and Tech Review
Provided a quote in 3 days, including a tech
review with the customer.
In-House Tooling Design and Build
Designed and built tooling in-house in less
than 2 weeks.
Prototype Division and Weld Team Efficiency
- Utilized the Prototype division for rapid prototyping and weld team to complete the first units in days.
- Submitted units to the customer for fit-up and provided on-site support.
Expedited PPAP and Production Ramp-Up
- Expedited PPAP approval.
- Ramped up production from 20 to 100 pieces per day over 2 weeks.
- Dedicated 5 welders to the project at the start.
Recognition and Additional Business
- Successfully delivered all 2,500 pieces.
- Awarded 50% of the production volume based on excellent quality and delivery performance.
Continuous Improvement and Cost Savings
- Proposed an improved robotic welding approach with high-volume tooling.
- Achieved a $437,000 annual cost savings and increased throughput.
- ROI on the new tooling was less than 4 months.
Recommendations
Leverage the success of this case study to
explore similar collaborative projects,
emphasizing rapid response, in-house
capabilities, and continuous improvement
for enhanced efficiency and cost savings.
Conclusion
The Rapid Rescue Case Study illustrates Alacriant’s dedication to overcoming manufacturing challenges with speed, precision, and innovation. The successful intervention not only resolved the immediate line-down situation but also resulted in long-term business growth through recognized excellence in quality and continuous improvement initiatives.
