How Metalgear Engineering Helped a Manufacturer Achieve a 10x Production Increase

Metalgear Engineering Delivers 10x Production Increase with Custom Automation Redesign

Assembly | PLC & Automated Systems | Custom Work Cells | Single-Piece Flow

A manufacturer working with a legacy product line of complex parts faced a significant bottleneck: their existing assembly process had no provisions for scalable production. With rising customer demand and output capped at 10 units per day, it was clear that incremental fixes wouldn't be enough.

Metalgear Engineering stepped in to redesign the assembly line from the ground up.

The Approach

Rather than patching an outdated process, Metalgear Engineering conducted a full redesign — implementing single-piece flow technology, custom-engineered work cells, and tailored PLC and automated control systems. Careful tool selection ensured that every stage of the assembly process was optimized for the specific demands of the product.

The Results

The impact was immediate and measurable:

• 10x increase in production output — from 10 units per day to 100
• 40% reduction in labor costs
• Improved product quality and consistency through more controlled, repeatable processes
• Reduced physical strain on technicians, resulting in a safer and more sustainable work environment
• The customer now has the capacity to meet growing market demand while maintaining a competitive edge

Takeaway

This project demonstrates what's possible when legacy manufacturing challenges are approached with purpose-built automation. By combining process engineering with custom PLC systems and smart tooling, Metalgear Engineering transformed a production ceiling into a scalable platform for growth.

Ready to scale your production?
Contact Metalgear Engineering to discuss how custom automation can transform your assembly process. Request a Quote