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Kenosha, WI 53144

Client: OEM -Hydraulics Industry

Topic: Conversion of worn out Cored Pattern to Hog Out from Ductile Iron Bar


Our client:

Needed to reduce the lead-time to produce, and deliver individual component parts; improve the part yield; reduce number of defects; and reduce the total cost of the part.

Selected GEM because of our ability to work with them to find solutions to their technology, process, quality, costs, and inventory needs. Our ability to provide a turn-key experience.

The challenges facing GEM included:

  • Sourcing pipeline of specific ductile iron bar sizing.
  • Develop tool paths that re-create the fluid passages that were previously cored in the original casting.
  • Maintain the quality standards with the new processes that the client had come to expect from us.

The actions we took to address these challenges included:

  • Developed Parametric Tool Paths incorporating the latest technologies from MasterCAM to mimic the fluid passages that were previously cored in the original casting
  • Developed strategic supply relationships to incorporate a stocking program of the ductile iron bar in the sizes we need when we need them.

Our actions resulted in:

  • Improved the product yield from 65% to 97% resulting in lower total costs.
  • Added in Kanban inventory system to smooth out the spikes in our customer’s demand.
  • Improved the lead-time from 15 weeks to 4 weeks to produce and deliver.

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