The Project

A large automotive customer in the automotive seating industry needed dozens of different ball sizes with minimal lead time.

Challenge / Goals

The customer faced a challenge in their stamping manufacturing process, where there was a high level of variability in the finished seat slide rails. To take up this tolerance and ensure a smooth feel for the seat maneuvering mechanics, the customer required dozens of different-sized balls to cover the range of spacing possibilities. However, the space needed to fill in each production lot of the rails was unknown until they were stamped. Therefore, the size of the ball needed to fill the rails varied from week to week.

With limited floor space, storing large quantities of different-diameter balls was nearly impossible. Longer production times for producing these balls could lead to line shutdowns until the correct size ball could be manufactured.

What Hartford Provided

Specializing in step-size ball manufacturing with ample warehouse space available, Hartford Technologies was able to step in and assist. Using its logistics acumen, production planning capacities, and warehouse space, Hartford manufactured and maintained a safety stock of all the sizes of balls needed. Millions of balls were manufactured and stored on a weekly basis for the customer, depending on their needs. Based on historical usage, feedback from the plant, and other factors, more product was made to replenish the safety stocks.

The Result

As a result of the partnership between Hartford Technologies and the customer, the customer was able to resolve their inventory and lead time issues. For the last 10 years, the customer did not experience a line-down situation due to a lack of the correct-sized ball. In addition, they were able to keep their plant free of pallets of step-sized balls that they wouldn't need for months or even years. As the partnership continued, the customer was able to more accurately predict the variation in rail tolerances, reducing the needed inventory and safety stock needed to be stored at Hartford Technologies.