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BHI Manufacturing Solutions

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Custom Metalformer Achieves Critical Part Requirements

A metal stamping assembly produced by BHI Manufacturing Solutions, an ISO 9001:2008 and AS9100C certified company with facilities in Garden Grove, Calif., and Tijuana, Mexico
Photo courtesy of BHI Manufacturing Solutions

In-house design assistance and engineering helps ensure quality for a wide range of metal formed parts

Mark Shortt
Editorial Director
Design-2-Part Magazine

BHI Manufacturing Solutions (, a custom metalforming company headquartered in Garden Grove, Calif., manufactures a wide variety of custom metal parts, including springs (compression, extension, torsion, and wire and flat springs); stampings (progressive, high-speed); wire form and flat strip products; and fourslide components (wire forms, clips, flat springs, and special brackets); and provides assembly and tooling. The company produces parts to exacting tolerances, with some dimensions being held to plus or minus one thousandth of an inch (0.001 inch), and tooling tolerances to tenths, or ten thousandths of an inch (0.0001 inch).

"With these exacting tolerances, you must have a specialized staff and equipment if you are to be a successful supplier to many of the industries that BHI Manufacturing Solutions has been servicing every day for over 50 years," said BHI Manufacturing Solutions President and CEO Javier Castro, in an e-mailed response.

The company's strict emphasis on quality was recently rewarded by one of its largest customers, which presented BHI Manufacturing Solutions with its 2013 Innovation Supplier of the Year award. The award was presented to the company with the notation, "In recognition of your superior design and engineering capabilities. Your valuable insight, innovation, and support reflect your dedication to being a leading edge provider."

Castro said that the award recognized BHI Manufacturing Solutions' redesign of a critical part that saved the customer over a half-million dollars per year. "This was accomplished by providing our customer with significant innovative ideas, prototypes manufactured, tooling completed, PPAP's submitted and approved, and the first two production releases completed, all in the same calendar year," he said. "This customer has over 800 suppliers worldwide."

BHI Manufacturing Solutions supplies parts to numerous industries, including aerospace; automotive; computers; defense; electronics; hardware; irrigation; medical equipment and devices; recreation; and telecommunications. With plants in the U.S. and Mexico, the company reports that it can offer customers shorter lead times, lower freight and custom charges, and fewer delivery delays than they would experience by offshoring to China. The company prides itself on its quality control.

Fourslide components, including a variety of wire forms, clips, and special brackets, are a specialty of BHI Manufacturing Solutions
Photo courtesy of BHI Manufacturing Solutions

"We operate in an extremely competitive market place where a variety of factors are involved," said Castro. "First and foremost is price. If your price is even marginally higher, you need to be able to demonstrate significant added value. At BHI Manufacturing Solutions, we do this in several ways. Whether it's a new or an existing part, our excellent in-house engineering department gets involved at the beginning of every project to ensure that consideration is given to the manufacturability, tooling complexity, material selection, and even the best manufacturing location to provide a quality product at the best possible price.

"Quality control is of paramount importance to us and both of our manufacturing facilities are AS9100C and ISO 9001:2008 certified," he continued. "With two plants, one in California and the other in Mexico, we can also offer shorter lead times, lower freight, no customs charges, and fewer delays than other low cost countries, such as China, and other offshore manufacturing centers. In addition, we offer a full range of Maquila services including warehousing; Kanban; virtual transfers; electronic data interchange, and vendor managed inventory to better service our customers' objectives of reduced inventory."

Engineering is one of BHI Manufacturing Solutions' main strengths, and the company offers design assistance from initial concept through prototype to finished product, Castro said. "Our engineers are ready to help with both existing, as well as new parts," he noted. BHI Manufacturing Solutions employs a "Design for Process Capability," which, he said, helps ensure a quality part at the best possible price. At this stage, the company can make many recommendations to save the customer time and money. "We can consider a wide range of materials, including exotic as well as common metals," he said. In addition, the company has a dedicated team of tooling designers and engineers that specialize in progressive dies, fourslide tooling, and compound and single hit dies. "Standardized tooling to precise customer specifications can be completed within 5 to 6 weeks, and we offer prototypes and short run assistance on new products," he added.

The year 2013 was a busy one for BHI Manufacturing Solutions. The company recently announced that it had doubled the size of its manufacturing facility in Tijuana, Mexico, increasing its company-wide manufacturing footprint to over 100,000 square feet. The new facility is located within the La Mesa Industrial Park, approximately 15 minutes from the San Ysidro and Otay Mesa border crossings in Tijuana ( Improving the company's quality system was also a major focus, as the company invested in new inspection equipment, software, and company-wide SPC, in addition to achieving AS9100C and ISO 9001:2008 certifications, Castro said.

This technical information has been contributed by
BHI Manufacturing Solutions

Click on Company Name for a Detailed Profile

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