Case Histories

 Emergency Support

OVERVIEW
A winter storm caused the roof to collapse at a key Jeep supplier for interior trim components. This damage completely shut down operations and would have severely disrupted production for their OEM customer.

SOLUTION
Their supplier immediately contacted the rapid response team at Decatur Plastic Products (DPP). Work was transferred within 24 hours and production resumed at DPP facilities.

SUMMARY
Quick yet high quality response resulted in immediate resumption of production. Components began shipping to the supplier's warehouse the next day, and Jeep did not lose even a single moment of production time. Best of all, there were zero quality defects throughout the entire production run, which lasted long after the damage was repaired and supplier was back in business.

LESSONS LEARNED
High quality doesn't preclude rapid response, but high quality combined with quick reaction is a rare resource that should always be part of your supply chain.

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 Innovation and Dependability

OVERVIEW
George F. Cram Company is the largest producer of world globes. They had also developed a proprietary process to manufacture their globes from material other than paper.

However, the complex process posed numerous challenges, not the least of which was transferring flat printing onto a spherical surface without distortion. Additionally, there was a requirement for 64 separate heat zones to insure exact and precise forming.

SOLUTION
The innovative professionals at Decatur Plastic Products developed processes and procedures that accounted for movement in the transfer from a flat surface to three dimensional objects. Additionally, many different heat zones are incorporated for precise control so that predictable and repeatable results were obtained each and every time.

SUMMARY
The customer had such faith in the integrity of the DPP team that they freely entrusted them with their highly proprietary process. Cram also had enough confidence in the company's capability that they selected them for this product innovation - a globe that could be internally lighted. The enhanced readability was a major factor in the product's spectacular sales success.

LESSONS LEARNED
A breakthrough idea takes both an innovative and experienced supplier whose expertise can help bring new products to market - fast.

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 Miracle Workers

OVERVIEW
A major supplier to Nissan had a sudden failure by one of their troubled providers. This disruption had to potential to severely impact production at Nissan and several other of their key OEM customers. The resulting loss of business would have been catastrophic.

SOLUTION
They immediately contact Decatur Plastic Products for help. Over that weekend, 16 molds were received, several of which needed repair before they could be used.

The DPP team jumped in immediately. The molds were repaired, production started and product shipped directly to the OEMs.

SUMMARY
On Monday morning, sufficient quantities were in place and none of the OEMs lost any production time whatsoever. This supplier became a loyal DPP supporter and today is the company's third largest customer.

LESSONS LEARNED
Don't wait until disaster strikes to find a dependable high quality supplier who can perform for you over the long term as well as in a crisis situation.

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 Past Performance Predicts Continued Success

OVERVIEW
When John Kussman acquired Decatur Plastic Products, he was already well known in the industry. His reputation was that of running innovative and efficient operations, which produced high quality parts and components, fiscally prudent management, reliable performance and outstanding customer support.

A former customer of John's at his previous company is a major supplier to well known original equipment manufacturers such as Honda, Toyota, Nissan and Acura. Upon John's arrival, his previous customer immediately contacted DPP about their new projects, based solely on their past relationship with him.

SOLUTION
Combining John Kussman's performance with the existing capability and expertise resident within DPP, the company immediately went to work supplying a wide range of products such as flocked glove boxes, console assemblies, arm rests, storage bins and door grips.

SUMMARY
Already high quality and delivery expectations were rapidly exceeded. The relationship that was based on a single individual quickly expanded to encompass the entire DPP team. Within three years, that customer grew to became Decatur Plastic Products' largest single customer.

While that position has now been taken over by the business growth of another organization, this organization is still the company's second largest customer. They also are the longest term DPP customer, with a relationship nearing three decades.

LESSONS LEARNED
Past performance, combined with the capability to unceasingly deliver even higher product quality and greater process efficiency, generates profitable and long term business relationships.

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