Situation
Leveraging in-house design and fastener manufacturing expertise,
centrally located, on-shore, near Chicago, Optimas rapidly developed,
produced, and delivered the M12 x 22MM Hex Cap Screw to meet
Cummins’ critical needs.

Optimas executed a multi-step, cold-head manufacturing process for an initial delivery of the critical fastener in only nine business days to ensure Cummins’ production continuity. With all production steps under one roof and key secondary processes within 15 minutes of production, Optimas ensured efficiency, speed, and quality control.

Some steps in the process:
1. Application Engineering/Drawing – Application engineers
worked with Cummins to determine requirements and ensure part
quality standards.

2. Engineering for Manufacturing – Engineers developed a production
road map, including tool and die development, raw material
acquisition, machine selection, run time and secondary process
partner recommendations.

3. Tooling – Tool and die makers used advanced technologies
and raw material relationships to accelerate tool development for
the pre-selected, in-house production machines.

4. Machine Time – Operators scheduled and staged the chosen cold headers, thread rolling and drilling machines to ensure a seamless production run.

5. Secondary Processes – A local secondary processor applied a
high-grade heat treatment and patch to optimize hardness, strength,
toughness and resist corrosion.

Results
In only nine days, the Optimas Quick Ship Program made an initial delivery of 29,500 engineered Hex Head Cap Screws to meet the immediate and critical supply shortage. Optimas delivered the remaining 170,500 pieces in multiple allotments within 21 days—well in advance of the anticipated delivery date.

In addition to Optimas’ efficient process, our unique ability to combine
high-grade heat treatment with roll threading—a capability few
manufacturers possess—ensured the part met Cummins stringent
quality requirements.