iCONN CASE STUDY
Company Reduces Costs, Improves Processes Through Reengineering

Background

Let’s take a closer look at how a self-contained breathing apparatus (SCBA) manufacturer lowered costs, improved quality and drove down the number of warranty claims by employing iCONN Systems as their partner for several receptacle connectors and cable assemblies.

Challenges

The client was working with a supplier that could not provide the value required to succeed in the marketplace. This led to poor service, quality challenges, and ultimately, warranty claims. These issues equated to higher costs and upset end users. In addition, delivery performance was inadequate, causing scheduling issues throughout the organization.

Solution

Gathering all the input from the client’s various departments, iCONN reengineered connectors and cable assemblies for increased throughput, and robust performance in the field. iCONN engineers adopt this mindset on all projects, and leverage design changes to address and eliminate quality and warranty issues while improving the assembly line process.

In parallel with reengineering, iCONN moved the client to a just-in-time manufacturing process — setting up a Kanban inventory stocking program, which allows iCONN and their customer to have a more agile, responsive production system.

Results

In a ten-month period of working with the client, iCONN:

• Saved the customer 30-35 percent on purchase price only
• Eliminated all warranty claims
• Improved assembly line processes
• Reduced production scrap
  
  

After the first full year of delivering product, the customer recognized iCONN as Supplier of the Year and designated iCONN as a World Class Supplier.

In seven years, iCONN solidified its partnership with the customer, increasing by four times the number of parts it manufactures for the company and becoming its preferred partner for all interconnect requirements. iCONN has expanded its role beyond connectors and cable assemblies by also providing subassemblies, including molded components.