Case Studies

Customer Challenge -
Cost Reduction
A prominent ceiling fan manufacturer was looking
to reduce the manufacturing costs, yet still maintain
a US manufacturing base. The key cost component
was the "end bell" of the fans.

The Greene Group’s Solution:
Greene's team of engineers and veteran toolmakers were able to design
and build a sophisticated deep draw die and press transfer mechanism.
This automated the stamping process, cutting production time and labor cost.
The customer could now justify keeping its manufacturing base in the US and
Greene became the sole source for this product.

Customer Challenge -
Product Transition on a Deadline
A leading automation and controls manufacturer needed to reduce costs and
improve quality on a mature product line with a six-month deadline. The product
line consisted of 190 different components, a variety of alloys, each with its own
stamping tool. In order to transition the company would need its supplier to be
six months.

The Greene Group’s Solution:
Greene Group was up and running on all 190 components in less than 6 months
on a Kanban system coordinating with the customer's maquiladora in Mexico.
The customer achieved a 25% savings in first year after transition.

Customer Challenge -
Prototype to High-Volume Production
A telecommunications manufacturer was in the
early design and development stages of a new
product that required a complex, tightly toleranced
copper metal component with zinc plating. The
customer required prototype and engineering
services on the front end, as well as long-term,
high-volume production capacity.

The Greene Group’s Solution:
We were able to assist in the design and prototype phase by quickly machining
samples for testing while simultaneously beginning work on a progressive die.
By the time the samples were approved, the production lead time was cut down
to several weeks and the customer was able to meet their time to
market requirements.

Customer Challenge -
Maintain High Quality with Reducing Cost
A prominent manufacturer of surgical instruments
was looking to eliminate the high cost of machining
on many of their components without sacrificing
quality and the ability to produce a complex shape.

The Greene Group’s Solution:
The MIM (Metal Injection Molding) experts at our Britt Manufacturing division
were able to design and build MIM molds for a variety of these very intricate
stainless steel components. The Britt team is now producing these components
and the customer is able to achieve a high level of quality at a significant
cost savings.

Customer Challenge -
Accommodate Complex Design
at Reasonable Cost
A large industrial manufacturer was looking to
produce a high quality copper component using the
metal injection molding process. This would allow
them to increase the complexity of the component
and reduce manufacturing costs.

The Greene Group’s Solution:
Britt Manufacturing was able to develop a process that included a custom copper
feedstock, unique mold design and sintering process. This process created the
high quality, complex shape the customer required. Britt is now in high volume
production on this component.