CASE STUDIES Case Study 1

"The good news…after a long delay, your project is back on. The bad news…delivery deadlines have not changed and now you need a miracle!"

Cast Products understands that even with all the best planning and anticipation, there are critical projects that require unique solutions. A good partner anticipates this need and stands ready with answers. In this scenario, Cast Products was able to drastically reduce the “time to market” for one of our customers when the call came in for production parts to be delivered in just five weeks.

The Challenge - A Midwest supplier of automotive hardware came to us with a “mission impossible” challenge from their CEO. The company wanted to introduce a new product line to their OEM customers at an industry trade show, but the problem was that the designs were just being completed. They needed a die casting company that could fabricate dies, provide samples, and ultimately deliver fully approved painted parts in five weeks. As an existing customer, they were familiar with our engineering strength and product quality, but we surprised them with our tooling solutions that made this project a reality. Since Cast Products designs and fabricates its own dies, we carry an inventory of common die components and in this case, we had approximately one third of the die completed when this customer placed their purchase order.

Our Approach - We worked with our customer’s engineering staff and developed solid models for the required parts in a few days. We engaged our critical suppliers, making them aware of our needs and securing their commitment. We designed the dies using our powerful Solidworks 2007® CAD Software and our MasterCam® Software to create the most optimal cutting programs. Our tool room operations ran around the clock, scheduling machines without disruption to any existing customers. We had our powder coating supplier staged to receive parts in order to meet shipping deadlines. We had quality controls in place at every step of the process to ensure that no re-work would be required.

The Result - In this case, tools were completed ahead of schedule, the customer was able to test samples for their new product line, and ultimately they introduced a new offering ahead of their competition at the trade show.