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Located in Elkhart, IN, Dynamic Metals, LLC, is a custom metal forming company specializing in complex shapes and tight tolerances for the aerospace, defense, automotive, and rail sectors.

Situation:

Several factors led to Dynamic Metals seeking assistance from Purdue MEP for Quality Management System support. First, the company’s clients were requiring the addition of aerospace certification AS13100. Second, there has been a high turnover of personnel who require training. And third, the volume of work has increased dramatically which requires the team to be more effective and efficient to complete the greater volume on time.

Solution:  

Purdue MEP provided quality training and consulting, as well as performed a QMS internal audit for Dynamic Metals. The quality training focused on Process Failure Mode and Effects Analysis (FMEA), Basic Statistical Process Control, Measurement Systems Analysis, and 8D Problem Solving.

Results:

Using the funding provided by the Office of Local Defense Community Cooperation (OLDCC) and the QMS expertise of Purdue MEP, Dynamic Metals has improved the quality of its products and increased the skills of its workforce. Aerospace manufacturing, whether commercial or military, comprises 80% of Dynamic Metals’ revenue. This is an increase from 60-70% in the last few years, and as indicated by these figures, aerospace manufacturing is a significant portion of its business. Without the Quality Management System (QMS) support, Dynamic Metals would have been in jeopardy of losing millions of dollars in the aerospace business because the various AS certifications are a contractual requirement.

Additionally, because they use a single QMS standard, the remainder of their business is positively impacted. For example, the QMS standard applied to their Tesla Megapack is the same as their DoD/aerospace applications. They produce structural components for the Megapack which is a powerful battery that provides energy storage and support, strengthening the sustainable energy infrastructure.

Impact metrics:

• Saved $18,000 on training and consulting costs due to grant funding
• Training for 41 individuals in a variety of quality concepts
• Secured current client base – protecting 80% of its annual revenue
• Heightened overall quality of all of its products due to all aspects of business following same QMS standards

“Supported by funding from OLDCC, Purdue MEP provided training that helped managers and operators understand the aerospace requirements. The professionals that came to our facilities were knowledgeable and very flexible with our work schedules.”

- Dave Ironside, Director of Quality, Dynamic Metals