In the first three months the teams collaborated on several significant design improvements on base units and enclosures. In the first collaboration, Muza identified the potential to improve the design of a base pad and reduce between 20 and 40 parts into 1 piece. Muza built the prototype units, went onto the production floor with the customer to evaluate how the prototype worked through the assembly process, and then provided additional design suggestions to help improve both safety and speed of assembly. Muza began supplying orders within 4 weeks once the new design was approved. The new design provided savings of over 20% per unit, but the real eye opener was the improvement in productivity in manufacturing. After the redesign, the customer improved base pad throughput from 1 unit a day to 5-6 per day, a 500-600% increase in throughput. Not only did Muza help the customer reduce assembly time and increase throughput by redesigning the unit, they also suggested changes in the assembly process to improve safety. In the second collaboration , Muza redesigned an enclosure unit. The new Muza design reduced the number of parts that needed to be assembled from 60 to 80 down to 1 piece. In this case the new part was more expensive than purchasing all of the individual parts, but provided savings on assembly that more than compensated for the higher part cost. The new design greatly improved throughput helping the customer build the same amount of finished units in 5 days that used to take 14 days. Muza also suggested several changes in the assembly process that improved both safety and throughput.“…they (Muza) were the first sheet metal fabricator supplier to suggest design and assembly changes.”
– Shannon M.
In the second collaboration , Muza redesigned an enclosure unit. The new Muza design reduced the number of parts that needed to be assembled from 60 to 80 down to 1 piece. In this case the new part was more expensive than purchasing all of the individual parts, but provided savings on assembly that more than compensated for the higher part cost. The new design greatly improved throughput helping the customer build the same amount of finished units in 5 days that used to take 14 days. Muza also suggested several changes in the assembly process that improved both safety and throughput. There were other benefits from the collaboration as well. The space needed to store the two new one-piece solutions (2 parts) vs. all of the old individual components (80 to 120 parts) was significantly reduced. Supply chain complexity and risk was minimized. Previously the customer had to deal with the risk of production being held up if one of 80 to 120 pieces was not available. Now their risk was only for 2 parts, much more visible and manageable. The customer is also able to save time and redeploy internal resources that had been required to do the enclosure UL certification internally.“My other sheet metal suppliers couldn’t provide lead times much better than 8 weeks. Muza is delivering new components in 4 weeks, existing components in 3-4 weeks, and beats that when we need them to expedite.”
– Shannon M.
Muza also greatly reduced the lead times for delivery. As noted by Shannon, General Manager for the customer, ‘With my other metal suppliers I couldn’t provide lead times much better than 8 weeks, and that was more of a hope than a promise. When we began working with Muza I asked multiple Muza team members about lead times. Every person was absolutely consistent in their promise – 4 weeks for new components and 3 to 4 weeks for existing components. Not only did they all promise the same delivery time, they have met that promise on every occasion and, on the occasions where we have asked them to help expedite, been able to beat that delivery promise. Good company, great story, nice people!’“Great company, great story, great people!”
– Shannon M.
