We've been manufacturing parts for one of our audio clients using their specified paint as requested. Everything seemed straightforward as the customer knew what they wanted, proven specifications that met all requirements.
But our finishing team kept noticing the same pattern: too many parts weren't making it through quality control because of finish inconsistencies and imperfections.
The Problem
The paint was from a reputable supplier but it was causing real headaches in production. While it was the desired colour and gloss level, the high reject rates were creating significant waste and cost because the finishing quality wasn’t good enough.
With such poor yield rates, the higher cost of production would eventually feed into higher customer prices. For their production volume, this meant £1000’s in wasted materials and time per year.
Rather than just accepting higher reject rates, we dug deeper to see if we could find a solution that saved them rejects and still delivered what they wanted.
Finding a Solution
Our team identified the main issue as the metallic paint not being a bonded product, making it susceptible to metallic clumps that create white spots. Working closely with our trusted paint suppliers, we identified bonded alternatives that delivered the exact same visual result but with much better application characteristics and they found it. The new option offered the same aesthetic requirements but with superior finish quality.
Making the Change
When we approached the client with our findings, they were open to testing the change. We presented our research showing how the alternative could solve their quality issues while maintaining their exact specifications.
They agreed to give it a trial.
The Results
The results delivered just what we wanted and more:
- Reject rates dropped by 75%
- Overall finish quality improved dramatically
- £1000’s saved annually in reduced waste and rework
Their feedback said it all: "That's a superb match and looks just like our original paint, but the quality is much better."
What This Means
This is what partnership looks like in manufacturing. When we see an opportunity to improve your product or process, we bring solutions, not just problems and higher prices.
The original paint wasn't wrong as it met specifications on paper. But sometimes following specifications exactly isn't enough when in reality, there's a better way to achieve the same result more efficiently and with better quality.
Because at the end of the day, your success is our success.
Looking for a manufacturing partner that actively looks for ways to improve your processes? The next improvement might be just one conversation away. Speak to us and let’s see if we can help you save money, time or both. Email us at sales@broxton.com if you’re interested.