Below are examples of cost-saving case studies that Falcon Metal clients have experienced by working with us to solve their inventory management challenges.

Customer #1

1. We implemented Falcon Metal’s FBIS Inventory Management Program, which eliminated 63 vendors over a 2 year implementation schedule.

2. FBIS freed receiving and material handler time, since a Falcon employee replenishes stock that has been consumed.

3. The company has an open purchasing position that was not necessary to fill due to outsourcing the Class “C” parts to Falcon Metal.

4. Currently, Falcon manages 625 items at 754 points of use in the plant.

5. Improved cash flow for customer by reducing the customer’s on hand inventory by over 50%. Point of use inventory is replenished on a “pull” rather than the traditional “push” basis. Falcon assumes responsibility for carrying the safety stock.

Customer #2

1. Falcon Metal bags the required part quantity and labels part numbers on all items per customer requirements. This saves the customer time and money in meeting its customer’s requirements.

Customer #3

1. Falcon Metal buys a number of components, assembles and bags with labels for kits, eliminating purchasing, warehouse and production employee labor.

Customer #4

1. Falcon Inventory Management System located at POU (Point Of Use) locations through the plant saves production employees time and aggravation. Only parts that are actually used in a specific location are stored, delivered and replenished there, making it easier to find and less movement to retrieve.

2. Falcon Metal worked with the engineering staff to consolidate 14 large, bulky items to 6 parts, reducing inventory investment, saving space and simplifying production employees’ procedures.

3. Due to market conditions and the economic downturn, Falcon worked with the customer to reduce inventory on hand by 75%. They continued to monitor bin quantities and adjust as needed to allow for maximum inventory turns. Currently, overall turns are at over 25.

Customer #5

1. Falcon took over an existing on-site inventory management program and immediately corrected the problems associated with downtime due to Class “C” components.

2. The original program consisted of approximately 180 items in 2001. Currently Falcon manages over 300 Class “C” parts. The products managed included molded plastic, screw machine parts, extrusions, stampings, solder, brazing paste, and sub assemblies.

3. Replenishment of inventory is done daily. The customer’s weighted average inventory turnover exceeds 52.

4. Falcon works with the customer’s engineering staff on new application and provides recommendations to reduce Total Procurement Cost for new products.