Case Study

Case 1: Factory Network Utilization

Inconsistencies in the cost and quality of small-lot products

Company A, which had to manufacture small-lot products of around 300 to 1,000 pcs/lot, was planning to place an order to an existing mass-production factory. However, the equipment and production methods do not meet the specifications and requirements, thus increasing the costs.

The company considered asking small and medium-sized enterprises to reduce costs but is worried with the quality of the products.

Company A is looking for a contractor/consignee that could clear up these inconsistencies.

Establish a consistent quality management system and successfully launched mass production

The NC Network OEM Department, which was consulted by our customers, decided to leave the factory selection as part of the purchasing function.

First, we listed factories from member companies that match the production method and quality required, then among of which selected the companies with the highest potential. However, it turned out that the forging factory could not provide a product warranty.

Immediately, NC Network checked into each companies' location and conditions and narrowed down the list of potential partner factories. Then, we set a consistent process: from forging to production, and confirmed that it was possible to start mass production.

Under normal circumstances, it is expected for either each factory to provide product warranty, but since there were no transactions between the two factories, NC Network provided help since the beginning. We provided a consistent quality assurance system and started the mass production.

Achieve approximately 20% cost reduction

We were able to achieve a cost reduction of about 20% compared with the time of requesting a small quantity lot product to an existing mass production factory.

Procurement costs can be reduced, including reductions in the number of management steps in purchasing.

By unifying and managing multiple factories, it is possible to use NC Network as a network that connects 18,000 member companies.

Case 2: Review of Mold Structure

Design a new mold structure with a significant improvement plan

In order to achieve improved cycle time, we collaborated with various factories, and came up with a new mold structure while taking into consideration the product requirements. In addition, we have adopted a large improvement plan such as how to control the cooling rate by aluminum alloy of the slide core; and the mold release method to the wing type.

Through repeated trials of the molding methods and molding conditions, of which were attended by the OEM Department, we were able to achieve an approximately 30% improvement in cycle time.

Succeed in achieving more than the target

We succedded in reducing 40 seconds/shot to 28 seconds/shot which is the average cycle time of a 200T molding machine. We were able to reduce the cycle time by 2 seconds lesser that the target.

The OEM Department is equipped with technical staff who have gained experience in each field and can respond quickly to technical issues.

In addition, in cases where issues cannot be resolved internally, external technical advisors will respond.

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