Case Study: Tortilla Oven Lubrication System
July 2, 2024
Motion Repair & Services Helps Steel Mill Standardize Splines, Saving $360K+ Annually
July 31, 2024
Customer Challenge
A leading steel tube manufacturer faced critical challenges when seeking to replace aging stand slide couplings:
- Excessive Lead Times: OEM replacement parts came with an 8–10 month lead time, posing a serious threat to production uptime.
- Prohibitive Costs: At $23,000 per OEM unit, the financial impact on the manufacturer was unsustainable in the long run.
Our Team's Solution
Understanding the urgency and the need for cost-effectiveness, our team implemented a multi-pronged approach:
- Reverse Engineering Expertise: Using a provided sample, our skilled engineers meticulously reverse-engineered the stand slide couplings. This guaranteed 100% compatibility with existing equipment and performance standards.
- Agile Manufacturing & Partnerships: By leveraging our in-house manufacturing capabilities and trusted network of partners, we streamlined the production process to expedite delivery.
- Cost-Effective Component Breakdown: Recognizing the opportunity for further savings, we offered the customer the flexibility to purchase individual coupling sections. This allowed for targeted replacement of worn parts, optimizing maintenance expenses.
Results That Speak for Themselves
- Substantial Cost Savings: Our team provided a cost-effective solution at a 15% reduction compared to the OEM price.
- Unmatched Lead Time Improvement: We drastically reduced the lead time from 8–10 months to 5–6 weeks. This minimized costly downtime for the customer and ensured uninterrupted production cycles.
- Enhanced Flexibility & Control: The option to purchase individual components empowered the customer with greater control over their maintenance schedule and budget.
Benefits That Extend Beyond the Bottom Line
- Significant Financial Gains: The customer saved an estimated $10,500 on the initial order of three units. This figure is further amplified when factoring in reduced shipping costs and minimized production losses due to downtime.
- Increased Operational Efficiency: The significantly shorter lead times translated to improved operational efficiency, allowing the customer to maintain production schedules and meet market demands.
- Foundation for a Lasting Partnership: Our solution-oriented approach and commitment to exceeding customer expectations solidified a strong, long-term partnership built on trust and mutual success.
Ready to optimize your steel manufacturing operations? Contact us today for a free consultation and discover how our customized solutions can address your unique challenges, improve efficiency and boost your bottom line.
