From Bottlenecks to Breakthroughs: How a Fabrication Leader Gained Efficiencyby Copper and Brass Sales

Case Study Summary

PROBLEM

A leading metal fabrication and assembly provider in the Midwest faced significant challenges due to reliance on subcontractors for critical processes as well as scrap management. Inefficiencies in these areas led to increased costs, excess material waste, and operational delays that limited their ability to scale effectively. Without an efficient system, they had trouble keeping production results consistently accurate. Without optimized processes, it was hard for them to grow in competitive markets where speed and quality matter most.

SOLUTION

By integrating with our in-house waterjet cutting, machining, and strategic supply chain solutions, the company eliminated outsourcing inefficiencies. The result: reduced costs, lower scrap rates, and a streamlined production workflow that enabled them to compete for larger contracts and improve profitability.

Introduction: Building a Competitive Advantage in Metal Fabrication

This customer has delivered a diverse range of metal fabrication and assembly services, including metal stamping, laser cutting, CNC punching, robotic welding, and powder coating since the 1960s. Despite decades of expertise and a strong industry reputation, our customer faced mounting challenges. Inefficient subcontracting and high scrap rates disrupted their production, driving up costs and threatening their competitive edge. They needed a smarter, more sustainable approach to remain an industry leader.

This case study demonstrates how we provided a strategic solution that not only addressed inefficiencies but also aligned with our purpose: We enable our customers to accelerate performance and increase value. By streamlining operations, reducing costs, and improving material utilization, we helped our partner achieve long-term growth and success.

The Problem: Subcontracting Inefficiencies and Scrap Waste

Our customer’s reliance on subcontractors for processes they didn’t have in-house, such as waterjet cutting. Outsourcing these services complicated their production and created barriers to scaling larger or more complex projects.

The Complexity of Managing Multiple Vendors

Managing multiple vendors introduced layers of complexity that disrupted efficiency. Relying on external vendors for various stages of production required separate purchase orders, shipping materials to subcontractors, and handling added costs upon receiving parts from multiple suppliers. This approach complicated procurement and led to logistical inefficiencies that slowed their production timelines, making it difficult to stay competitive in a fast-paced market.

Scrap Handling and Environmental Impact

Managing scrap was another major hurdle, particularly with the rise in environmental standards. Outsourcing parts to various vendors meant limited control over scrap generation, making it difficult to minimize waste. The high scrap rates not only inflated material costs but also created sustainability challenges as more material waste required disposal or recycling. This was a crucial issue, as our customer operates in sectors like power distribution, where environmental compliance and efficient material use are key to maintaining credibility.

The cumulative impact of these challenges made it difficult for our customer to compete with larger companies that could manage these processes in-house and minimize waste more effectively. They needed a streamlined solution to handle production more efficiently, reduce scrap, and maintain sustainable practices without sacrificing quality or speed.

Our Solution: Streamlining Production and Reducing Waste

Guided by our purpose—We enable our customers to accelerate performance and increase value—we partnered with them to provide a solution that consolidated essential services, simplified vendor management, reduced scrap, and enhanced their competitive position in the market. By bringing services in-house and developing a customized supply chain solution, we helped address their most pressing operational challenges.

Eliminating Outsourcing Challenges with In-House Waterjet Cutting

The first step in our solution was leveraging our in-house waterjet. We used our waterjet to cut their complex shapes which eliminated our customer’s need for external vendors of that type. We reduced the number of touchpoints and simplified the production process. Our in-house team could provide near-net shapes from ITAR-compliant prints, cutting components more precisely and minimizing excess material waste.

This precise approach delivered parts that were closer to their final dimensions, reducing the need for further machining and material handling on the partner’s end. By combining these tasks internally, we cut costly shipping and handling fees while ensuring that materials arrived on time and to specification, supporting efficient assembly and faster project turnaround.

Expanding Capabilities with Router Cutting and Machining

In addition to water jet cutting, we provided router cutting and machining services, further reducing our partner’s dependency on subcontractors. This consolidation under one roof allowed them to rely on a single vendor for multiple stages of production. Not only did this minimize the handling of materials, but it also reduced potential delays and errors, ensuring consistent quality, and streamlined operations.

How In-House Processing Reduced Scrap and Costs

One of the most valuable outcomes of this partnership was a significant reduction in scrap material. Previously, our partner’s scrap was handled by subcontractors. With our precise cutting and machining capabilities, we were able to produce near-net shapes that minimized excess material while handling their scrap for them, providing a more competitive cost at a better rate.

Cost Savings and Efficiency: A Competitive Advantage

The monetary impact of our solution was considerable. By reducing costs related to material procurement, scrap handling, and vendor management, our partner could bid more competitively on contracts and take on larger, more complex projects that were previously out of reach.

The streamlined processes allowed them to increase throughput and take on added projects without compromising quality. With our support, they were able to complete assemblies for high-profile clients, securing new contracts and expanding their customer base. This increase in project scope and operational capacity enabled sustained growth, positioning our partner as a viable competitor to larger firms.

Measurable Success: Efficiency, Cost Savings, and Market Growth

Since partnering with us, our customer has experienced significant growth, driven by improved operational efficiency without delays, cost reduction, and simplified vendor management. With fewer vendors to coordinate, lower scrap rates, and precise delivery timelines, they’ve reduced overall handling costs and positioned themselves more favorably in the market.

Facing Similar Challenges? Let Us Help.

In today’s competitive market, efficiency, precision, and waste reduction are critical to success. Whether you’re struggling with subcontracting challenges, excessive scrap, or inefficient vendor management, our tailored materials solutions can help.

We provide in-house processing, strategic supply chain solutions, and precision cutting technologies to help manufacturers reduce costs, improve lead times, and scale efficiently.

Contact us today to discover how our solutions can help you streamline operations, reduce costs, and achieve your goals faster.