Outsourcing the fabrication and assembly of sheet metal subcomponents used in a larger, complex product made operational sense. High volumes, aggressive fulfillment, and duplicating the customer’s in-house quality control complicated finding a contract manufacturer with the systems, processes and capital commitment required to perform as a key supply chain partner.

Schaffer Manufacturing took on the project in 2013. Collaborating on a complete outsourced manufacturing solution, from operation set-up to daily production, has included several major undertakings and requires operating what is essentially a dedicated “factory within a factory.”

  • Developing custom tooling. A significant amount of custom punch tooling developed specifically for this project includes consolidating eight different hits into a single tool. Similarly, at the press brake, a six-foot part initially required two operators and multiple passes to make the necessary bends. Schaffer developed one tool that achieves three bends, and installed an assisted lifting mechanism that requires just one operator instead of two.
  • Verifying high-volume operations. A steel-threaded PEM insert, press-fit into a precision-made hole, is more efficient than tapping. But the process requires an efficient, thorough and foolproof verification process to check every one of several dozen insertions included on a part which Schaffer manufacturers by the thousands each month.
  • Processing and managing materials at high volume. Each month, Schaffer produces thousands of assemblies which include five component parts. The project consumes a high volume of materials, from sheet metal and rivets to hardware. At 77 rivets per assembly, for example, each 1,000-piece lot requires 77,000 rivets managed on a JIT basis with the fastener vendor. Similarly, Schaffer collaborates with the metal supplier to maintain a perpetual inventory, using a two-week supply, that doesn’t overburden the vendor.
  • Providing intensive quality control documentation. To mirror the customer’s rigorous reporting standards, each Schaffer operation includes its own quality inspection documentation. From tracking the heat numbers for steel to lot tracing for hardware and rivets. Schaffer then uploads all digitally scanned documentation to the customer.

In addition, Schaffer continually fine tunes every system, process and detail to create a total, integrated production solution that fits seamlessly into the customer’s manufacturing operation. Right down to processing parts and assemblies in pallet-sized batches; a stacking strategy that utilizes reusable dunnage to protect an awkward-to-transport part; and inventory managed on a pull basis to meet daily orders.

Outsourcing the fabrication and assembly of sheet metal subcomponents used in a larger, complex product made operational sense. High volumes, aggressive fulfillment, and duplicating the customer’s in-house quality control complicated finding a contract manufacturer with the systems, processes and capital commitment required to perform as a key supply chain partner.

Schaffer Manufacturing took on the project in 2013. Collaborating on a complete outsourced manufacturing solution, from operation set-up to daily production, has included several major undertakings and requires operating what is essentially a dedicated “factory within a factory.”

  • Developing custom tooling. A significant amount of custom punch tooling developed specifically for this project includes consolidating eight different hits into a single tool. Similarly, at the press brake, a six-foot part initially required two operators and multiple passes to make the necessary bends. Schaffer developed one tool that achieves three bends, and installed an assisted lifting mechanism that requires just one operator instead of two.
  • Verifying high-volume operations. A steel-threaded PEM insert, press-fit into a precision-made hole, is more efficient than tapping. But the process requires an efficient, thorough and foolproof verification process to check every one of several dozen insertions included on a part which Schaffer manufacturers by the thousands each month.
  • Processing and managing materials at high volume. Each month, Schaffer produces thousands of assemblies which include five component parts. The project consumes a high volume of materials, from sheet metal and rivets to hardware. At 77 rivets per assembly, for example, each 1,000-piece lot requires 77,000 rivets managed on a JIT basis with the fastener vendor. Similarly, Schaffer collaborates with the metal supplier to maintain a perpetual inventory, using a two-week supply, that doesn’t overburden the vendor.
  • Providing intensive quality control documentation. To mirror the customer’s rigorous reporting standards, each Schaffer operation includes its own quality inspection documentation. From tracking the heat numbers for steel to lot tracing for hardware and rivets. Schaffer then uploads all digitally scanned documentation to the customer.

In addition, Schaffer continually fine tunes every system, process and detail to create a total, integrated production solution that fits seamlessly into the customer’s manufacturing operation. Right down to processing parts and assemblies in pallet-sized batches; a stacking strategy that utilizes reusable dunnage to protect an awkward-to-transport part; and inventory managed on a pull basis to meet daily orders.