Worldwide Integrated Resources

The Basics

WIR's OTC Metal Fabricating program offers a unique combination of services and processes under one roof. We're able to handle the entire project, from conception through completion. We can simplify every step of your project. In fact, we know of no other company that can offer you the variety of manufacturing services provided by WIR.

WIR brings to its operation the unparalleled services, attention to detail, and quality performance you'd expect from an industry leader. We have expanded our services to become your only single source for:

By letting WIR handle your project from start to finish, you'll save on development, production, transportation and inventory costs. And you'll receive your finished product when you need it.

Metal Fabrication

WIR's OTC Metal Fabrication Program caters to the specific manufacturing needs of our customers. The focus of this program is to implement efficient sheet metal manufacturing processes developed by our Design, Engineering and Prototyping staff.

WIR's approach to sheetmetal design, prototype and process engineering ensure the development of cost effective sheetmetal products. WIR's customers demand a wide range of metal fabricating services to meet their needs. To meet their custom metal forming needs, we offer the following metal fabrication services:

WIR operators are skilled craftsmen with many years of metal working experience. Precision tolerances are their standard. Their ability to handle intricate design and parts is something our clients have appreciated from day one.

Our equipment is modern, versatile, and adaptable to a wide variety of tooling designs. It ranges from giant hydraulic presses to multipurpose welding machines that were actually designed for our facility.

Punching, forming and welding processes, metal stamping capability, combined with JIT production techniques provide an opportunity to establish vertically integrated manufacturing cells. These dedicated cells are designed and fitted to programs that can best realize optimum cost benefits from a custom arrangement, of machine tools and fabrication processes. We also support customer individual piece part requirements by either conventional batch manufacturing or JIT. Shipping requirements driven by MRP or JIT are manufactured and shipped in accordance to either a flexible customer demand-pull, or a fixed shipping schedule.

WIR's Tool Design staff uses state-of-the-art design software, which allow us to import customer designs. A significant reduction in lead-time in the manufacture of hard tools is realized with the integration of the customer's CAD design, tool design software interpreting the language and the machine tool program conversion. For optimum time to market considerations, WIR has established a tool building network of suppliers around the world who are converting our CAD tool designs into a machine tool language.

Materials

The following is a list of materials we utilize in fabricating quality metal parts:

Assembly

WIR's OTC Metal Fabrication Program assembles mechanical and electrical components including terminating, soldering and bonding, screen printing, parts marking, finishing and packaging. We offer a broad spectrum of operations from short run to high volume with manual and semi-automatic assembly procedures. By working closely with our clients, we have been able to achieve the lowest possible assembly costs while still maintaining our thorough quality control standards. WIR offers superior quality and on-time delivery.

To see more on our assembly and packaging...see our section on "Assemblies"

Prototyping and Development

WIR realizes that sound product development processes form the foundation for successful product launch and production. Our basic philosophy surrounding this process is that the product must be engineered before any design activities can take place. Therefore, engineering and design are different activities. Design is the process of creating parts and assemblies that form the product. Engineering is the foundation that must be built before any design activities take place. WIR takes pride in our expertise and ability to build this foundation, which will decrease your time to market and give you a successful product release.

WIR's engineers are experienced in the design and manufacture of metal parts and sub-assemblies. Tool and die design and procurement, component design and development, and special production equipment design are all accomplished by our engineering staff. WIR offers a wide variety of prototyping and development options, including:

WIR has a separate prototype facility that is dedicated only to product development activities. This focus allows us to minimize development costs and development time.

The prototype and engineering departments have a seamless integration with our production manufacturing facilities. This integration allows us to transfer your product from prototype to production quickly and efficiently, helping you meet your cost targets and timelines.

WIR’s staff is capable of designing across a broad range of materials and works closely with our customers right from the beginning to ensure the exact and precise mechanisms to provide quick delivery and fast, turnaround response.

WIR’s engineering staff has been created with the philosophy that sound engineering practices form the basis for a successful product development program. Our engineers stay well-versed in the latest technologies surrounding product development.

We encourage early involvement of our staff with your design team, relying heavily on our expertise to guide you in making choices surrounding fabrication and assembly decisions. When budgetary and delivery restraints begin to invade the development process, we can help make tough trade-off decisions so deadlines are met. Our engineering staff will also focus on manufacturability and design cost reduction, insuring your product assembles efficiently and at the least possible cost.

Currently, our engineering staff has three major focuses in the product development area:

• "Turnkey" engineering and design product development service.
• Engineering and design support for product you are developing. When an engineering or design "spike" hits your development cycle, our staff can fill in when you might be short-handed.
• Evaluation of products currently in production with the goal of identifying cost-reduction opportunities through design modifications. After a product goes into production, there is always room for improvement. Our engineers will look for these improvements with a keen focus on maintaining system requirements, making intelligent recommendations for cost reduction.

Our dedicated and talented team of engineers are well trained and experienced in all aspects of product development, with the focus of helping you get you product to market in the leaset time possible.

Quality Control

WIR's quality control program is comprehensive, complete and effective. Our philosophy is to build quality into our products through the selection and application of suitable raw materials, the definition and implementation of optimum production standards, the proper control and evaluation of our processing techniques, and the selection and use of effective packaging systems and transportation alternatives.

In our fabrication department, we use Statistical Process Control for consistent production within critical product dimensional tolerances. X, R and P charts are used for true process control or for audit process control. Quality assurance practices include Statistical Process Control, calibration, and inspection procedures, all documented for each individual component or assembly in our Quality Assurance Manual.

We have quality/reliability engineering expertise to implement reliability testing, where required. WIR uses various computer techniques, including Statistical Process Control and quality cost systems, which allow automatic report writing of numerical summary data and access to all individual data. All manufactured parts receive either SPC or 100% visual inspection and roving inspection.

The Finishes

WIR's OTC Metal Fabrication Program offers many services to put the finished touches to your product, component or sub-assembly. We are able to offer brushed finished metals, powder coating, and wet painting. We can also silk-screen legends or logos on your products. A short list of these services include:

• Plating: Anodize, Chemflim, Zinc, Tin, Nickel, and Galvanizing
• Electrolysis - Nickel and Cadmium
• Black E-Coating (Low and High Volume)
• Graphics Overlay
• Painting - Water Based & Powder
• Powder Coating (Wide Array of Colors)
  • Polyesters
  • TGICs
  • Urethanes
  • Epoxies
• Silk-Screening
• Assembly and packaging