Problems we have solved
Slashing costs by repurposing existing assets
Our Client needed a new barricade wall that cost around $50,000. S3 inventoried the client’s facility and discovered 3 partial and dismantled barricade walls. For only $5,000 these walls were reconditioned and modified to completely meet the required specifications. The Client was very pleased with the $45,000 savings.
Improved quality management = improved business
S3 was hired by a company that had been put on a “Non-approved Supplier List” by their customer. The company hired S3 to assist them in implementing a quality management system that was compliant to ISO 9001. The company was later audited by their prior customer which resulted in the company being moved to the “Approved Supplier List.” The next year, this company was runner-up for their customer’s “Supplier of the Year” award.
Stamping out quality issues
A machine shop housed a press that was used to stamp parts for one automotive customer. The machine shop hired S3 to implement an ISO9001 Quality Management System with the scope identified as the stamping process and its supporting processes. After nine weeks of working with S3, the stamping process received ISO 9001 Certification by Eagle Registration. The entire job was trouble-free and very affordable.
More case studies
Root Cause Analysis
Problem:
S3 was hired to travel to the client’s subsupplier and conduct root cause analysis, hoping to eliminate two recurring problems: military ammunition components that 1) were bent and 2) had rust spots on the parts.
A thorough analysis of the issue revealed a dual root cause:
- The outsourced heat treating process SOPs were not being followed which resulted in a small number of bent parts.
- The outsourced plating process preventive maintenance was not being conducted on their chemical tanks, causing uneven coverage which allowed red rust spots.
Solution:
Upon communication with the client, S3 issued action items to the subsupplier. The problems did not recur.
Cost Estimation Analysis
Problem:
A client had inadvertently under quoted (in the millions) on a project. S3 was contacted by the client asking for assistance with lean activities that were associated with the poorly quoted project. S3 conducted a risk assessment that encompassed customer requirements, schedule, resources, and finances.
Solution:
S3 created and led an internal team and saved the client $4 million in three days. The client subsequently hired S3 as lean consultants for the duration of the project.
Supplier Development
Problem:
A client called with purchasing/acquisitions issue concerning a financially struggling subsupplier. The client was concerned that the subsupplier did not have the ability to meet timing and cost.
Solution:
S3 conducted a full assessment of the subsupplier and determined that assistance was needed to meet the requirements. S3 led the subsupplier to meet the required schedule and cost.
Procurement/Acquisition
Problem:
The client called S3 with the problem of an incompetent subsupplier. A machine was ordered; with the delivery time only 6 weeks out, the client contacted the subsupplier for an update and was told that the machine build had not yet started.
Solution:
With S3 assistance, a new subsupplier was located and the machine build was re-sourced. The machine arrived in 6 weeks, all requirements met, and the cost fell under budget.
Lean Manufacturing
Problem:
An S3 client had current assembly rate of 5 minutes per product. The desired rate was 1 minute per product.
Solution:
S3 was contacted. After investigation, S3 rearranged the line layout, built assembly fixtures, trialed process flow, wrote work instructions, and trained staff. The changes that were made in the process met the client’s desire of 1 minute assembly rate per product.
Resourcing
Problem:
S3 received a call from an automotive client who was having a resource issue. They needed 200 PPAPs updated to meet customer requirements.
Solution:
S3 provided a Quality Engineer with extensive automotive experience to review, correct/update and submit all the PPAPs, per the customer requirements.
Document and Data Control
Problem:
An automotive client contacted S3 with a systematic failure in their Quality Management System documentation. All FMEAs were found to be missing significant updates and Engineering changes. The client had a TS 16949 Surveillance Audit coming up and was nervous about the condition of the FMEAs.
Solution:
S3 provided all the resources needed to update and correct all FMEAs in time for the audit. No issues were found.
