At Wolfram Manufacturing we use mature project planning and execution to meet any customer challenge. One such challenge involved a customer with a strong product line and in house production capabilities that was looking for a 5x increase in production capacity, a decrease in material consumption, and reduced lead times on their parts. Wolfram was able to keep pace with the customers ability to procure material and in 3 months their dream was a reality. Wolfram has produced roughly 10,000 of the parts made from Durabar Cast Iron to date. Our current steady capacity for these parts is about 6,000 per month with surge production easily over 10,000.
By working closely with purchasing we’ve been able to time our deliveries to our customer’s needs and increase production from 300 units per week to 1,500 units per week on average. Communication with Quality & Engineering departments have made this part so stable that Wolfram was the first supplier this customer chose to start a reduced internal inspection program. To achieve the steady state run rate many tools were deployed – thoughtful process design, active machine in-cut monitoring, robotic machine tending, and statistical automated machine offsetting. To make sure the capacity was reliable and available in a surge we tooled up to make sure the part can run on 2 additional machines not in the cell – and all 3 of them concurrently when needed. This gives us the flexibility to increase production to 2,500 per week, about 10,000 per month but also achieve truly exceptional accuracy to our customer need dates.