Build a stronger supplier base in Eastern Europe

An industrial manufacturer needed to move thousands of machining hours for a diverse portfolio of complex stainless-steel components out of internal production. The parts required different machining processes, specialist capabilities and careful supplier allocation.

BSN structured the portfolio by manufacturing requirement, identified and qualified a network of Eastern European machining suppliers, and matched each part family with the supplier best suited to its technical demands.

Thousands of machining hours were successfully transferred, relieving internal capacity and establishing a more resilient supplier network. Total cost was reduced by more than 20% compared with internal manufacturing costs.

A long-term strategic supplier unexpectedly announced the discontinuation of complex, safety-critical sheet-metal assemblies, creating an immediate risk of production interruption. These components had historically been considered difficult to relocate, with supplier qualification estimated at approximately 12 months.

BSN launched an accelerated replacement process, identified a capable Eastern European supplier, coordinated the technical qualification and prepared the new source for serial production within three months.

Production continuity was secured, the supply interruption was avoided, and serial deliveries from the new supplier were successfully launched.

A leading European machinery manufacturer was experiencing recurring porosity in large brass castings produced by conventional gravity casting. Defects were often discovered only during internal machining, causing rejected components, lost machining time and additional cost. Increasing the casting allowance would have reduced the quality risk, but at the cost of heavier castings, more material and substantially more machining.

Instead of increasing the casting allowance, BSN developed an alternative manufacturing concept together with an Eastern European supplier: centrifugal casting combined with supplier-side pre-machining. Centrifugal casting reduced the risk of porosity, while the supplier removed and recycled excess material before delivery, leaving only the required finishing allowance.

Casting reliability improved, internal machining time was substantially reduced, and total cost fell by more than 25% compared with the previous manufacturing solution.