The Client

A global leader in variable speed drives and control systems, won a large-scale government infrastructure project to provide advanced energy storage and rapid power diversion to critical infrastructure in the energy sector.

A contract manufacturing partner that could deliver both technical precision and the ability to scale quickly, with deep experience in precision metal fabrication and PPAP compliance was needed for a project of this size.

The Challenge

The scope and requirements of the infrastructure project were unlike anything the company had faced before.

Not only would it require producing thousands of precision metal parts each month, but every component had to meet the stringent regulatory demands of the automotive-grade Production Part Approval Process (PPAP).

For Mathison Manufacturing, this project presented an exciting opportunity to flex its muscles with an all-hands-on-deck approach.

Traditional PPAP and First Article Inspections (FAIs) were labor-intensive, involving manual measurements and handwritten records that could stretch on for weeks. Meeting the company’s requirements — and those of the government — required investments in additional resources, software, and digital quality systems to measurably boost efficiency.

Game on.

The Solution

Mathison’s team began by reassessing its processes from the ground up, investing in advanced inspection software that automated the generation of bubble drawings, recorded measurements digitally, and streamlined compliance documentation—all aligned with ISO 9001:2015 standards.

What once took weeks could now be accomplished in a fraction of the time, with optimal accuracy, traceability, and lean manufacturing efficiency.

At the same time, Mathison strengthened its quality department by bringing in an experienced leader with ISO 9001:2015 and lead auditor credentials—someone capable of not only managing the demands of the DOE project but also building a stronger quality system for future work in regulated industries such as medical, aerospace, and green energy.

Recognizing the volume requirements, Mathison also invested in specialized forming equipment dedicated to producing the company’s parts. This investment allowed production to scale without sacrificing precision, ensuring throughput could match the government’s aggressive timelines.

From the earliest stages of the project, Mathison worked side by side with the company’s engineering team, collaborating on design for manufacturability (DFM), anticipating potential roadblocks, and adapting seamlessly to design revisions. This partnership-based approach allowed the teams to maintain momentum even when specifications shifted midstream.

The Result

Mathison delivered government-compliant parts on schedule, cut inspection times by more than half, and built scalable quality processes now serving customers in industries like medical, aerospace, industrial automation, and green energy.

More importantly, the experience deepened the trust between Mathison and the company (their customer), solidifying a partnership built on transparency, adaptability, and a shared commitment to excellence.

Discover how Mathison Manufacturing can help you maintain competitive costs while keeping your production proudly American-made. Contact us at info@mathisonmfg.com.