Zero Cases, one of the world’s leading manufacturers of protective cases, containers and enclosures, is aiming to strengthen its foothold in the aerospace market.
The company’s comprehensive portfolio of products ensures cargo and equipment, everything from laptops to engines, are fully protected when transported by air (or by land and sea). In addition, its enclosures are used to house vital electrical sensors, systems and components that are integral to planes, helicopters, rockets and satellites.
These cases and enclosures, designed and manufactured at its Smethwick factory, are engineered to meet and exceed the most extreme aerospace specifications in terms of performance, reliability and safety. Made of plastic or aluminium, they are lightweight yet immensely strong, and offer maximum protection against shock and vibration.
Zero already has an impressive client list that includes Boeing, Learjet, Cessna, Gulfstream, Lockheed Martin, EADS (owners of Airbus) and Rolls Royce. While it remains committed to its defence, industrial and medical markets, Zero is keen to develop its aerospace business by forming closer working relationships with OEMs.
“This is a strategic change of direction for us, working more with primes and tier ones while continuing to work with suppliers further down the chain,” said Zero’s plant manager Mike Dimmack.
“What has happened in the past is that if we received an order for a case, we supplied that case, but sometimes the product supplied to the end user was not quite right and this then involved modifications and retesting.
“But if we are involved in the decision-making process from the very start, we can provide a tailor-made solution which we know will meet the customer’s precise requirements. By getting closer to the customer, we can be their systems provider rather than just a product supplier.”
Zero believes one factor which underpins its success in all its global markets is keeping it local – sourcing from the region products, such as fasteners, and raw materials, such as foam.
“Where at all possible, we are extremely keen to use the local supply chain,” explained Mike. “When we have sourced offshore the decision was solely a financial one because the quality of suppliers has always been better here.
“But we are finding that the Black Country and the West Midlands are becoming more competitive again for sourcing products that are typically used in our industry. When you also consider transportation costs, logistical problems, import/export controls, getting through customs and potential language barriers, buying local becomes even more attractive.”
Less reliance on suppliers in countries such as the USA and China also means Zero can reduce stock levels, in keeping with its recent adoption of lean manufacturing techniques throughout its operations.
As part of a five-year plan, the company says it is “reinventing” itself as a lean manufacturer. The majority of its 25 employees, both on the shop floor and from within the management team, are currently undergoing NVQ training in lean philosophy and processes.
All this is helping Zero to meet increasing customer demands for shorter lead times. “We can’t compete with the very cheap offshore producers on price,” said Mike, “but we are looking to be a more added-value provider, aiming to deliver and provide cost-effective solutions quicker than anybody else.
“It used to take us six weeks to turn round a standard item. Now we can have products manufactured and shipped within a maximum of four weeks.
“We’ve just achieved this for one of our biggest customers. They placed an order with us at the beginning of October for 110 aluminum cases and they were all dispatched by the end of the month.
“Shorter lead times will help us to help our customers react quickly to changing requirements in the marketplace.”