A true relationship between a custom part supplier and a customer is built on more than just parts. When an OEM sought a second source for a custom TPE component Timco proved to be a collaborative partner that delivered a more efficient, transparent solution for these highly custom parts.
The Challenge: Limited Visibility and Single-Source Risk for a Critical Component
The challenge started with a need to reduce risk. The customer’s unique component was used within its own production process, making it essential for the equipment that enabled their entire operation.
If supply of this component was disrupted, it wouldn’t just impact a single product line. That distinction made the risk of having a single source even greater. What compounded the issue was that the OEM lacked visibility into the process for how these unique parts were manufactured. As a result, the customers faced:
- Single-source dependency: The component was sourced from one vendor, creating potential supply chain risk.
- Lack of transparency: The existing supplier was unwilling to work collaboratively to identify solutions that would provide redundancy in the supply chain.
- Limited internal knowledge: The OEM had a specific understanding of how the component worked to optimize their manufacturing process, however did not fully understand the unique processes required to manufacture this crucial component.
- Need for a reliable backup plan: The goal wasn’t immediate replacement, but risk mitigation through a qualified second source.
Timco’s Approach: Reverse Engineering, Collaboration, and Process Innovation
Rather than simply quoting the part, Timco took a deeper, collaborative approach to understand the “why” behind the request before determining the “how.”
Start with Discovery
Timco starts every project with a conversation because success depends on more than just a quote request and a drawing. We worked with the OEM to uncover the full context for their parts:
- How each part functioned within the manufacturing process
- What failure modes mattered most
- What level of precision and consistency was required
This process helped define the true performance requirements of the parts. It also allowed Timco to identify potential opportunities to improve the components instead of simply delivering something that was “good enough.”
Reverse Engineer the Parts with Limited Information
The OEM provided Timco sample parts and a basic, high-level drawing with limited detail. From there, Timco had to take a few steps to provide recommendations based on the part’s specific requirements:
- Analyze the part’s geometry and material behavior
- Identify critical features and tolerances
- Determine viable manufacturing methods
This process required a combination of experience, engineering support, and trial-and-error development to build a repeatable solution. The result was that Timco could identify the core requirements for the part and determine ways to improve on the original version.
Identify a More Efficient Manufacturing Method
While the original component was molded, Timco didn’t want to simply duplicate the original manufacturing process. We sought to identify an alternative approach that enhances the overall process while delivering the same functional outcome.
After comparing different options, Timco recommended a custom manufacturing process to create the TPE component. This method introduced several potential advantages:
- More continuous and efficient production
- Reduced labor and handling
- Improved consistency across runs
- Elimination of certain failure risks inherent in the currently used process
Leverage Global and Local Supply Options
The key to choosing between domestic and offshore sourcing is to determine the right fit for your specific situation. To balance cost, quality, and responsiveness for the OEM, Timco implemented a hybrid approach.
We were able to leverage our offshore resources to develop tooling overseas and shipping the tooling for domestic manufacturing. This approach allows the OEM to benefit from:
- Cost-effective development resources
- Reliable, onshore production
- Greater control over supply chain logistics
Maintain Transparency and Collaboration
The final step of the process was to ensure that the OEM didn’t endure the same challenges they had with their original supplier. We openly engaged with the customer so that they had a better understanding of the sourcing process.
While proprietary details were protected, the OEM gained confidence and clarity due to:
- Open communication throughout development
- Visibility into the manufacturing process
- Ability for the OEM to audit and understand how the part is produced
Results: A Clear Path to Supply Chain Stability
Key Outcomes
- Established a viable second source strategy for a critical manufacturing component
- Developed an alternative production method that improves efficiency and consistency
- Delivered initial samples that closely match performance requirements
- Created a collaborative, transparent supplier relationship
- Positioned Timco as a potential primary supplier based on performance and partnership
Building More Reliable Supplier Relationships, One Project at a Time
Most businesses need more than just parts. Your organization deserves a who work with you to understand your components, improve them, and reliably supply them.
For the OEM, our role was to provide clarity, flexibility, and collaboration to a process that previously lacked all three. That transparent process allowed us to not only replicate an existing part, but create an improved, more reliable sourcing strategy.
Ready to partner with a custom rubber and plastic part supplier who works with your business instead of simply accepting quotes? Give us a call at 800-969-6242 or contact us online to get a quick, tailored quote for your applications.
