Client Overview

Industry: Voice and Data Communications

A leading voice and data communications specialist sought a more durable and efficient enclosure solution for their network service operations (NSO). Their existing supplier only provided thin plastic enclosures, which were prone to breakage, leading to frequent service calls and increased costs. They required a partner who could deliver a more robust, reliable, and installation-friendly product while maintaining supply chain consistency.

The Need

The client faced several key challenges that necessitated an urgent redesign of their enclosure solution:

1. Fragility of Existing Enclosures
• The previous supplier only offered enclosures made of thin plastic, which were highly susceptible to cracking and breaking.
• Frequent breakages led to increased service calls, maintenance costs, and a decline in customer satisfaction.
2. Inefficiencies in Installation
• The original enclosures did not include pre-punched cable entry knockouts, requiring technicians to manually modify them on-site.
• This process was time-consuming and introduced inconsistencies in installation, delaying project completion.

Challenges

• Material Durability
• Plastic enclosures could not withstand operational stress, requiring frequent replacements.
• A metal alternative was necessary to improve reliability and longevity.
• Installation Delays
• Without pre-installed cable knockouts, technicians had to drill openings on-site, slowing down installation and increasing labor costs.

The Solution

Electron Metal developed a custom-engineered metal enclosure solution tailored to the client’s needs. The design improvements included:

1. High-Strength Metal Enclosure

• Replaced plastic with durable, high-grade metal to enhance resilience and extend product lifespan.
• Eliminated breakage-related service calls, reducing long-term maintenance costs.

2. Pre-Engineered Installation Enhancements

• Incorporated custom-sized cable entry knockouts based on the client’s specifications.
• Removed the need for manual modifications on-site, streamlining installation and improving consistency.

3. Structural Reinforcement and Packaging Upgrades

• Introduced a reinforced "lip" around the door opening, preventing warping or bowing during transit.
• Redesigned packaging protocols to ensure enclosures remained structurally sound during shipment.

Implementation Process

The project followed a structured and collaborative development process to ensure a seamless transition from design to deployment:

1. Reverse Engineering & Custom Design
• Electron Metal analyzed the client’s existing enclosures and identified areas for improvement.
• The engineering team incorporated client-requested modifications, including precise knockout placements for optimal cable entry.
2. Prototyping & Validation
• Prototype enclosures were produced and sent to the client for evaluation.
• The feedback loop allowed for refinements before full-scale manufacturing began.
3. Quality Assurance & Structural Testing
• Comprehensive stress tests were conducted to validate enclosure durability and performance under real-world conditions.
• Packaging methods were optimized to prevent damage during transit.

Results & Benefits

The client experienced significant operational improvements after implementing Electron Metal’s solution:

Enhanced Product Durability

✔ The transition to metal enclosures eliminated breakage-related service calls.
✔ The client now offers a superior, long-lasting product that enhances their reputation in the industry.

Increased Installation Efficiency

✔ Pre-installed knockouts significantly reduced the time required for on-site modifications.
✔ Installation workflows became faster, more streamlined, and more consistent.

Cost Reduction & Operational Savings

✔ Decreased service calls and replacement costs due to improved enclosure durability.
✔ Reduced installation labor hours led to overall project cost savings.

Stronger Market Position & Business Growth

✔ The client transitioned 100% of their metal enclosure procurement to Electron Metal.
✔ The improved reliability of their infrastructure enhanced their credibility as a provider of high-quality communication solutions.

Client Feedback

"Electron Metal provided not just a better product but a better process. We were extremely satisfied with their responsiveness and quick resolution of any issues we had, providing  a solution that streamlined our operations. We have since transitioned all of our metal enclosure requirements—both standard and custom—to Electron Metal due to the quality of the product and the exceptional service we received."— Client Engineering Team