Our client, a leading supplier of workplace health and safety solutions, was facing significant challenges in managing their sub-assemblies internally and were seeking a solution to streamline their operations and reduce the burden on their internal resources. The primary issues included:
The Challenge
- Supplier Management: Coordinating with multiple suppliers was time-consuming and complex.
- Resource Allocation: Managing sub-assemblies took up valuable time for the client’s staff, detracting from their core activities and not adding significant value.
- Operational Complexity: Setting up their own assembly line would have required substantial investment and effort.
They were particularly interested in finding a single supplier who could handle all their sub-assembly needs for their Cone Barrier System, used for traffic and car park management. This complex product comprised a range of parts sourced from multiple suppliers. They reached out to BSA who had been providing them with injection moulding services for several years, including several components within the Cone Barrier System, to see how they could help.
The Solution
BSA Mouldings addressed these challenges by offering comprehensive sub-assembly services. The key aspects of the solution included:
- Sourcing and Stock Holding: BSA sourced parts from various suppliers globally, including the UK and China. Components such as springs, screws, and specific tapes were procured to meet the client’s requirements. A dedicated KanBan system was implemented and inventory levels equivalent to 3 months stock were established and maintained.
- Advanced Assembly Techniques: BSA utilised techniques like hotplate welding, ultrasonic welding, and heat staking to assemble the parts. The assembly process was tailored to the client’s specifications, ensuring high-quality output.
- Integrated Services: BSA provided additional services such as picking, packing, and arranging distribution to various countries. This end-to-end service significantly simplified the client’s supply chain.
- Quality Assurance: BSA’s trained staff ensured that each assembly met stringent quality standards. The use of a KanBan system helped streamline the assembly line and maintain efficiency. These processes have ensured that over the last 2 years, BSA has consistently achieved 99% OTIF performance.
The Results
The partnership with BSA Mouldings brought several advantages to the client. By having only one supplier to manage, the client experienced reduced complexity and administrative overheads. The integrated services provided by BSA streamlined shipping processes, which sped up lead times and improved overall efficiency. Outsourcing sub-assemblies allowed the client to reduce their inventory levels, freeing up capital and storage space. Additionally, the streamlined process and reduced supplier management led to significant cost savings. With BSA’s robust quality assurance processes in place, the incidence of defects and warranty claims was also reduced, further enhancing the client’s operational efficiency. This ‘One Stop Shop’ approach was highly valued by the client as it allowed them to place orders and have products delivered directly to their customers. BSA’s ability to hold stock of completed products enabled immediate delivery, further enhancing the client’s operational efficiency. BSA Mouldings’ commitment to excellence was recognised with an award for Top Supplier of the Year, achieving a 99% on-time delivery success rate.
