Case Studies

Case Studies

CPI SHROUDS

In February 1995, IDOT called us to assist them in the development of a new product.  They had originally asked the Pole Manufacturers to develop a product that would encapsulate the bottom of the Mast Arm Pole to conceal the bolts, nuts, flanges and wiring.  The Pole Manufacturers did not develop a suitable product; therefore, we were consulted.  At the time of their call, IDOT had already written this product into the specs for the June 1995 letting, so time was of the essence.  After hearing the specific criteria, we went to the drawing board.  Our design for CPI's Shroud was met with immediate acceptance, and was enhanced with a few features, which went beyond the original scope of the requirements.  The benefits derived from using the Shroud are aesthetics; improved pole life; coverage of all bolts, nuts, flanges, and wiring; elimination of normal maintenance; and elimination of animal nesting and breeding.  Component Product's Shroud is the only one approved by IDOT, and is being used at all new and/or rebuilt locations.  

This is one of several innovative products to be designed and produced by CPI. 

CPI POST TOP MOUNT

While conversing with several Installation Contractors, the need for improved fixtures for mounting traffic signal lights was discussed.   After reviewing the shortcomings of the previously specified fixtures and listening to the defined requirements, we decided to build a better mounting system.  Initially we sketched a rough design in order to "visualize" our product.  We then further discussed the design with contractors to ensure all needs were met and all problems eliminated.  Our next step was to prototype the product.  Once the prototype was approved, full production was a go!  As such, we developed a new Polycarbonate Fixture (patent pending) - Component Product's Post Top Mount (CPI-PTM-1).   

This weather resistant, lightweight fixture incorporates the following new and improved features:  multiple head mounting positions, safety in a knockdown situation, and close set mounting to move lights nearer to the pole to avoid turning vehicles.  CPI's Post Top Mount, in conjunction with our Side of Pole Bracket and Poly Mounting Hardware, offers reduced installation time, decreased labor costs, increased durability, and competitive pricing.  Our Post Top Mount is also maintenance free.

FINISHES

Painted Poles and Bases had been the preferred coating for many years, but as maintenance costs increased, the need for maintenance-free products became a must!  In the late 80's, CPI worked very closely with IDOT Officials on prototype samples of Galvanized Poles and Bases.  Once the benefits were shown, the finish specifications were changed.  CPI's next undertaking was to convince the counties, municipalities, and villages about the benefits of galvanized products.  This was accomplished, and Galvanized Poles and Bases are now the standard.  

An additional problem concerning finishes arose, and CPI was again consulted.  In this situation, Painted and Powder Coated Poles and Bases were required, but due to the high concentration of de-icing salt used, these products could not stand the test of time. After researching the problem, CPI came up with a solution: CPI Plasticoat.  This is a heat applied coating which can withstand extreme conditions, offering excellent protection from sunlight, salt, and temperature.  Not only did we solve our customer's problem, we have also helped many others: this coating has been used on equipment along highways and bridges in inter-coastal waterways and ocean front areas. 

MACHINING

When Component Products, Inc. manufactures machined parts for our customers, we want to deliver more than just a product at the right price and within a specified amount of time.   Our team, for example, asks questions concerning fit, function, and packaging.  Because, not only do we want to deliver an acceptable product to you, on time, and at the right price, we also work to build you a better product to fit your needs.  It is this very attitude that has "opened the door" for us with many Plant Managers, Purchasing Agents, Engineers, Research and Development Officials, and Production Personnel.  These relationships, built on a common goal - making the best possible product for you, have helped solve problems such as the following:    

•	A Vice President of a Refrigeration company contacted us as he was having severe problems with welding their fittings onto tanks.  They were averaging 15-20% rejects.  We worked closely with them to develop Tangential Fittings.  Tangential Fittings are now produced for them to fit the exact size of the pipe, to which they are welded.  Previously the fittings were miter cut, which left areas the weld would not completely fill.  Not only does the Tangential Fitting look better, but our customer has received a significant savings by eliminating duplicate fittings, cutting, re-welding, and re-testing costs.  All of this equates to a better product with substantial cost savings.  Today, their rejects are less than 1%.

•	We worked very closely with an Engineer in Research and Development for our customer in the Water Treatment Industry to develop a new product.  This product is a housing for filtration which they previously could not produce economically.  Consequently, they were losing market share to their competitors.  After experimenting with different types of material and various ways to seal this material, we developed a product that won immediate acceptance.  This product has allowed them to regain their market share. 

•	We pride ourselves on our material expertise.  As such, one of our customers was having difficulty locating special alloy material.  Because of our vast knowledge of material sources, we were able to locate exactly what was needed at a competitive price.