RELY · Case Study · Program transferNO. 13
PROGRAM TRANSFER AND CONTRACT ASSEMBLY · MEDICAL PRODUCTS
Moved in from out of state. Running in under four weeks.
A Wisconsin injection molder wanted mask assembly moved from out of state to sit closer to its molding operation. RELY time-studied the work so the labor requirement was known before the move, then had production running in under four weeks.
The first program was masks. Within months, the same customer had moved six more product lines to RELY.
- <4 wksFrom go-ahead to production at RELY
- 104,609Medical masks assembledApril 2021 to May 2022
- 307,347Molded components assembled into masks
- 7Product lines for the same customerMasks, then six more
The risk was the gap between the old line and the new one.
The customer’s mask assembly ran out of state, far from its Wisconsin molding operation. Before committing to a move, the customer needed real numbers on labor content and throughput. Once the decision was made, any gap between the old line stopping and the new one starting put supply at risk.
WHAT RELY OWNED
- Time study before the moveMeasured the assembly work so the move decision rested on real labor data.
- Fast startProduction at RELY in under four weeks from go-ahead.
- Cleaning, kitting and GMPRan under RELY’s GMP policies, with cleaning and kitting built in.
- Three sizes, one processSmall, medium and large masks assembled under one controlled program.
- Peak monthly outputMask output peaked at 17,375 in September 2021.
- Bagged and packed outMore than 102,000 masks individually bagged and packed for shipment.
WHAT THE PROGRAM GREW INTO
One fast start became seven product lines.
- APR 2021
Medical masks
104,609 units. The first program at RELY.
- MAY 2021
Portion trays
41,666 units.
- MAY 2021
Crowfoot holders
19,433 units.
- JUN 2021
Pivot pins
24,507 units.
- JUN 2021 TO MAR 2022
Three smaller lines
20,474 units.
First run at RELY for each line. The six additional lines were molded parts that needed assembly, kitting or packout.
ACROSS THE RELATIONSHIP
- Total units, seven product lines
- 210,689
- Period
- April 2021 to August 2022
- Masks in the peak month
- 17,375 (September 2021)
Includes masks and the six additional product lines. This is not a mask total.
A specific transfer need became a broader manufacturing relationship once RELY showed it could execute.
SOURCE: RELY ERP RECORDS. MASKS: 31 COMPLETED WORK ORDERS, APRIL 2021 TO MAY 2022. PRODUCT LINES: APRIL 2021 TO AUGUST 2022. HISTORICAL PROGRAM; PHOTO FROM THE 2021 PROGRAM. CUSTOMER NOT NAMED. RESULTS REFLECT THIS PROGRAM ONLY AND ARE NOT A STANDARD LEAD-TIME OR CAPACITY COMMITMENT.
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