The Key to ‘Prodigy’

Donnelly Manages 40 Parts for Scotsman Icemaker Launch
Like many successful OEMs, Scotsman Ice Systems recognizes the value of leveraging the expertise of a focused supplier base.

In order to do so, the leading innovator of ice technology must demand a lot from each supplier partner. That’s especially true where new product development is concerned—because getting high-quality new products to market quickly and at a competitive cost is essential to the Vernon Hills, Illinois -based company’s continued growth.

Such was the case when Scotsman set out to create the Prodigy product line, the next generation of its smart, energy-efficient ice machines. With so much riding on the success of this powerful new product, Scotsman officials knew they needed the help of valued partners from the very beginning.

Scotsman called on its longtime injection molding supplier, Donnelly Custom Manufacturing Company, to manage a complex process from start to finish involving 40 injection molds and related plastic parts, sourcing molds in China and ensuring a high-quality product, shipped on time and on budget.

Gold Supplier Award Winner
At Donnelly, we dove right into the project, thanks to our strategic model of customer intimacy, which drives our people to provide extraordinary value and service to a focused base of customers—“all for some, not some for all.”

Over the long-standing relationship between our two companies, we have gotten to know and understand Scotsman’s business. No wonder Donnelly has received Scotsman’s Gold Supplier award multiple times. The annual award is given to Scotsman’s top 10 suppliers (out of more than 200) based on quality, on-time delivery and costs.

Facilitating Sourcing in China
Donnelly is committed to acting not just as a supplier, but as a business partner with the expertise to get things done right—from tool design to quoting, approval and execution. Involving us at the beginning of the Prodigy process meant that our team could provide value by minimizing costs—and producing the necessary—speed to market.

Due to cost constraints, the molds were sourced in China. Global sourcing can be risky in terms of quality and delivery, but our experienced team has long traveled to China to set up an effective process. This approach ensures that tight budgets, quality standards and delivery times were met.

“There are so many considerations in the molding process, and the Donnelly team brought their expertise to all of them—including long-distance sampling and troubleshooting,” said Scotsman’s Alex Harvey. “Their help was essential to producing parts that are easily manufacturable.”

A Well-Honed Engineering Process
The complicated transfer of the 40 molds easily met launch deadlines. The smooth translation of Prodigy’s imaginative design into low-cost, high-quality components was made possible by our refined engineering model:

• The Manufacturing Launch Engineer applies significant tooling knowledge to develop the most manufacturable part.
• The Process Engineer ensures that—the parts are manufactured to quality specifications as well as on time and on budget.
• The Project Engineer has overall responsibility and accountability—for project management, including up-front engineering, part design—and tool transfer.

Assembly, Logistics and More
Donnelly also added value to the process with assembly, shipping and inventory management. Throughout the launch process, our team met budgetary and timeline requirements. In the end, Prodigy launched as planned, and to great reviews, in late 2006.

“Donnelly’s people understand our business and the industry better than anyone else,” said Harvey. “When Donnelly recommends something, you can count on it.”