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High Volume of Metal Stampings and Busbars

Project Overview

A leading global manufacturer of electrical automation and control solutions required a dependable partner to manage the high-volume production of metal stampings and busbars across multiple product groups. These included both regular repeat items and spot-ordered parts delivered to multiple international locations.

Challenge

The customer faced complex demands, with a large number of unique part numbers and challenging lead-time requirements — often needing next-day delivery. Components required numerous processes including stamping, laser cutting, forming, tin, silver and zinc electroplating, assembly, and welding. In addition, multiple ordering methods created administrative inefficiencies, and maintaining a delivery performance of over 98% on-time-in-full (OTIF) was critical.

Solution

H V Wooding implemented a project-managed approach, conducting a detailed evaluation of lead times, batch sizes, and delivery frequencies. Consignment stock, Kanban, and Vendor Managed Inventory (VMI) systems were introduced where beneficial, ensuring smoother production flow and inventory control. Our in-house developed Buffer Management System was used to schedule work, prioritise production, and maintain internal target stock levels. With all manufacturing processes carried out in-house, H V Wooding provided a highly responsive and integrated solution.

Results

Lead times and batch sizes were significantly reduced, resulting in a faster and more reliable supply chain. Delivery and quality performance remained consistently high, with simplified ordering processes reducing administrative time and cost. The customer benefited from improved service levels and greater production flexibility, supported by H V Wooding’s ability to respond rapidly to changes in demand.

Added Value

Through this partnership, H V Wooding improved delivery performance to 99% on-time-in-full, achieving a quality rate of just 150 PPM. By introducing consignment stock and reducing supplier complexity, the customer cut overall ordering and invoicing costs by 30%. A long-term framework agreement was established, securing continued year-on-year cost savings and supply chain stability.

Trusted by Leading Brands

H V Wooding works with world-class names across the electrical, energy, medical, and aerospace sectors, where precision and reliability are vital. Clients such as Schneider Electric, Honeywell, Rolls-Royce, and GE Renewables continue to rely on us for our expertise, quality, and long-term partnership approach.

Commitment to Quality

As an ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018 certified manufacturer, H V Wooding ensures every component meets the highest standards of precision and consistency. Our in-house Buffer Management System, advanced metrology equipment, and commitment to LEAN manufacturing and continuous improvement guarantee world-class results in high-volume production environments.

Laser Cutting

H V Wooding provides precision laser cutting services in copper, aluminium, and electrical steels for laminations, busbars, and complex components. We deliver fast-turnaround prototyping and mid-volume production with tight tolerances and clean edges.

Wire Erosion

H V Wooding provides precision wire erosion (EDM) services with tolerances down to ±5 microns. We manufacture components for the aerospace, EV, medical and research sectors, offering exceptional accuracy, clean finishes and rapid turnaround.

Presswork & Tooling

H V Wooding designs and manufactures precision press tools and provides high-quality presswork for a range of industries. Our in-house toolroom ensures fast turnaround, consistent quality and cost-effective solutions from prototype to volume production.

Busbar Manufacture

H V Wooding designs and manufactures precision copper, aluminium and flexible busbars for power, EV and renewable energy systems, with full insulation and finishing options.

Electroplating

In-house electroplating in tin, zinc, nickel and silver. Rack and barrel options, with lab and X-ray testing to ensure coating accuracy, durability and quality.

Assembly

Mechanical, busbar and general sub-assembly services. Welding, fitting, packaging and line-side delivery with ISO-certified quality and cost-effective outsourcing from H V Wooding.

Electrical Switchgear Manufacturing Solutions

Supporting our customers manufacturing world class products in the Electrical Switchgear, Power Generation and Power Distribution markets.

Data Centres

Supporting our customers manufacturing world class products in the Data Centre sector, producing Busbars for switchboards, distribution boards, battery banks and IT infrastructure solutions.

Science & Research

We have gained a solid reputation for the supply of magnet assembly low carbon steel Yokes and stainless steel Collar laminations for prototype and upgrades to the Hadron Collider. Customers include; CERN, CEA, Elytt and Brookhaven.

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