Project snapshot: a UK manufacturer of recycling and material sorting equipment needed a stainless steel fabrication partner for 316L hoppers, guards and control enclosures. Over 14 months the project moved from a single trial order to a quarterly release schedule, with lead time reduced by 35% and first-pass yield raised from 88% to 98.5%.

Client Background

The Problem

The client had been buying fabricated 316L parts from a local UK subcontractor. Three issues kept repeating. First, delivery slipped: quoted at 8 weeks, actual delivery ran to 12 weeks in peak season, which pushed machine assembly dates and forced expensive overtime. Second, weld quality was inconsistent. Hoppers that must hold liquid were failing leak tests on roughly one unit in eight, and rework had to be done after powder coating, which meant stripping, re-welding and recoating. Third, dimensional drift appeared on multi-part assemblies: brackets that passed inspection individually would not line up on the assembly line, because each part had been made from a different drawing revision.

Cost per part looked acceptable on paper, but the true cost including rework, line stoppage and air freight for urgent replacement parts was far higher than the purchase price suggested.

What We Changed

• Drawing and revision control: one master drawing set was locked at project start, and every batch was produced against the same revision with a revision stamp on each part
• Welding fixtures: jigs were built for the three highest-volume weldments so hoop distortion stayed within 1.5mm and leak tests became repeatable
• First article approval: a full first article with CMM dimensional report and weld photographs was approved before any batch production
• Material traceability: 316L mill certificates were filed per heat number and referenced on the packing list
• Kitting: parts for one machine were packed and labelled as a kit rather than as bulk quantities, cutting line-side sorting time
• Surface treatment: powder coating applied after all welding and leak testing, with 480-hour salt spray verification on test coupons

Execution Timeline

1. Week 1: drawing review, DFM report issued with 11 cost and quality suggestions
2. Week 2: quotation approved, NDA signed, welding jigs designed
3. Week 3 to 4: first articles produced and shipped by air for approval
4. Week 5: client engineering sign-off, minor bend radius change incorporated
5. Week 6 onwards: batch production in 3-week cycles, sea freight with 2 weeks buffer stock at client site

Results After 14 Months

Client Feedback

"The difference is predictability. We stopped building buffer stock to protect our assembly line, because the parts arrive when promised and they fit the first time," said the client's purchasing manager. "The DFM notes in the first quote paid for themselves in the first three batches."

Why The Project Worked

Three things made the difference: fixtures instead of skill-dependent welding, one locked drawing revision across every batch, and inspection data shipped with the parts so the client could verify rather than guess, and a single English speaking engineer accountable for the account.

Similar Project?

We fabricate 304 and 316L parts for recycling equipment, food machinery, medical housings and water treatment systems. Send your drawing with material, thickness, finish and annual quantity, and our engineering team will reply with a costed quotation and DFM notes within 12 working hours.