The Objective
Due to an unforeseen plant closure of the incumbent injection molder, the customer was left without a manufacturing solution and insufficient inventory to meet immediate demand. An urgent transfer of multiple tools was required.
The Challenge
A medical OEM was facing dire supply chain issues, but only had a limited safety stock of various sized components needed for a wound retractor. These medical instruments require final assembly of the addition of a film by the customer, which are then delivered directly to the healthcare provider.
Changing to a different molder would solve the supply chain issues but required the transfer of four tools used to mold six differently sized rings. The medical OEM wasn’t sure if the transfers could be completed without running even further behind.
In an abbreviated timeframe, Allegheny had to source material, evaluate and repair all tooling, sample and execute an expedited validation.
The Solution
We assigned an in-house integration team composed of tooling, process and quality engineers to manage the project from tool receipt to validation completion. The team completed many tasks in parallel where feasible, including prioritizing machine availability with the production department. Our commitment to close collaboration with our customer enabled us to process validation approvals in a timely manner, and facilitating immediate production.
Utilizing steps in our proven 5-step process, we were able to meet the exact needs of this customer to their specifications. By streamlining the necessary protocols, our team was able to move the molds to our facility with minimal involvement from the OEM. With the tool transfer and validation complete, we began manufacturing. The OEM was able to resume manufacturing of the surgical instruments, and back on track with delivery schedules with the health care providers they supply.
“Our history of thriving in high-speed development cycles in the space and defense industries uniquely positioned us to have the skill set and resources available to meet this challenge,” said Robert Stutzman, CEO. “While the products may be different, the expectations and challenges facing our customers are the same.”
