AccuGlass, Inc. is a recently formed manufacturer looking to establish itself as a leading glass supplier to the appliance market. Based in Ambridge, just west of Pittsburgh, the company employs approximately 40 people and posted sales of more than $4M. AccuGlass’ products are used in applications such as cooktops and oven fronts for OEM customers, who demand exceptional quality from suppliers.
Because AccuGlass supplies glass materials to an industry where product quality is essential, any new suppliers to this market are scrutinized closely until they have a proven track record. During the summer of 1998, AccuGlass was offered the opportunity to quote on new cooktop parts from a large appliance OEM customer. Winning the bid required AccuGlass’ certification of the parts quality through the customer’s qualification process. After review, AccuGlass’ management decided that they did not have the internal resources or expertise to meet the certification requirements without outside assistance, so they contacted Catalyst Connection.
Based on AccuGlass’ service needs and time constraints, Catalyst Connection identified an independent consultant with expertise in parts qualification to provide the needed assistance. Catalyst Connection coordinated the project with the consultant to work directly with AccuGlass in completing the parts qualification process. AccuGlass’ customer was requesting that it qualify the parts through a documentation process involving Failure Mode Effects Analysis (FMEA) gage repeatability and capability studies (gage R&R) process capability studies, quality plans and process flow plans. The independent consultant worked with the company employees to understand the requirements of AccuGlass’ customers, perform the necessary studies and complete the supporting documentation. With this assistance, AccGlass was able to meet the customer’s product quality requirements and sample and documentation timetable.
As a result of this effort, AccuGlass was approved as the supplier for the cooktop parts. The projected impacts from this assistance include: - A 30 percent increase in annual sales over the next year - A three-fold increase in employment due to the increased sales - Improved part quality through the identification and minimization of potential sources for manufacturing defects - An increase in market share and increased acceptance as a qualified supplier to the appliance industry