Besides the items bulleted below the real added value our current customers are telling us are how we make new projects a success, have consistency of supply, flexible manufacturing, stable pricing, delivery performance, high quality and great deal of experience.
- Design for injection moulding
- Project Management
- UK Toolmaking
- In-cycle: insert moulding, over-moulding and sub-assembly
- Post-moulding: Pad transfer printing, ultrasonics, machining and sub-assembly
What a major blue chip customer said was….
New Project success
Kavia has a lot of experience in delivering projects for customers and us. Review the design and project management tabs for further information. Another key factor is to bring key elements such as toolmaking local and under control.
Consistency of supply
Kavia has a small manufacturing team totalling 19 and with an average time of service of 14 years. Coupled with the directors are hands-on with running production, taking orders, planning production and managing raw material stock offers our customers extremely close familiarity ensuring consistent injection moulded components. Our 8 Arburg machines are all less than 10 years old (purchased between 2004 – 2009) and very well maintained. If we do have a tooling issue it can be resolved with internal engineering resource or by our local tooling partner offers same day service.
Kavia runs a manned day shift and lights-out operations. We can cater for small and large production runs. On new projects we will help the customer with component design and tool configurations to give them the greatest manufacturing flexibility versus capital investment. Our sub-assembly service is now trending towards finished goods assembly in some cases. This offers the customer a much leaner supply chain and distribution point making further financial savings.
The cost breakdown of an injection moulded component can be split into two major elements, the raw material and the manufacturing costs. Kavia buys larger batches of raw material to cover extended periods so the customer benefits from scales of quantity and longer periods without price changes. Manufacturing costs and overhead are closely reviewed on a monthly and annual basis. Of course energy and labour are major factors so Kavia is always pushing for ways to improve efficiency and increasing our lights-out/automated production ratio.
Kavia measures our delivery performance independently from our customers’ processes so we can set our own targets for improvement. In a typical month there would over 120 deliveries going out or 6 per day. We measure: number of items delivered complete, items part or zero delivered (very low number) and items on time even with order corrections in same week of dispatch.
High quality Moulding
Kavia moulds over 250,000 plastic components per month, quality performance is reviewed at the quarterly management meeting and all recorded corrective actions the period are discussed. As an example in the last quarter there was just 7 reported issues in 750,000 parts delivered.
Experienced injection moulding company
The company is approaching its 35th anniversary in 2014 and the current senior management team has been around for 25-28 years of that so this offers great continuity and knowledge. With a manufacturing team with 13 years average time served is a great backup ensuring care is taken over every moulding and customer account.