How Belden Universal Optimized Capacity and Saved $110K Annually
Driving profitability through precise forecasting and labor optimization.
Belden Universal, , a premier manufacturer of high-quality universal joints, achieved $110,000 in annual savings by implementing Amper’s manufacturing intelligence platform. By gaining real-time visibility into machine and labor utilization, Belden Universal saved $60,000 in labor costs and deferred $50,000 in capital investments. This case study highlights how accurate, data-driven forecasting allows manufacturing leaders to uncover hidden capacity, optimize workforce scheduling, and scale operations without unnecessary overhead.
The Challenge
The High Cost of Inaccurate Forecasting
Before Amper, Belden Universal struggled with "invisible" capacity. Without real-time data, the leadership team had to rely on manual estimates to determine if they had the machine time and labor required to meet customer demand. This lack of precision led to:
- Over-scheduling labor, resulting in unnecessary overtime costs.
- Difficulty identifying which machines were underutilized.
- Pressure to purchase new equipment despite having untapped capacity in existing assets.
The Solution
Precision Planning with Real-Time Data
Belden Universal deployed Amper to create a "single source of truth" for their production floor. By tracking every minute of machine activity and correlating it with labor shifts, they transformed their planning process.
Key Solutions Implemented:
- Utilization Tracking: Real-time monitoring of machine uptime vs. idle time.
- Labor Optimization: Aligning staffing levels with actual machine demand to eliminate waste.
- Capacity Forecasting: Using historical performance data to predict future throughput with 100% confidence.
The Results: Measurable Financial and Operational Impact
Total Annual Savings: A combination of labor efficiency and avoided capital costs.
Saved in Labor & Uptime: Achieved by optimizing shift schedules and reducing machine idle time.
In Deferred Investments: By uncovering hidden capacity, Belden avoided the immediate need for expensive new machinery.
Scaling with Confidence
For Belden Universal, Amper isn't just a monitoring tool—it's a growth engine. With the ability to forecast accurately, the company can now take on more complex projects and larger orders, knowing exactly how much "runway" they have on the shop floor. This data-backed approach ensures that every investment in labor or equipment is timed perfectly for maximum ROI.
“We’re able to see where the work is, where we have capacity, where we need to add capacity. Being able to forecast in a very precise and accurate way is essential, and we wouldn’t know that without Amper.”
Streamline production monitoring & drive continuous improvement
Frequently Asked Questions
Case Study Insights & Implementation FAQ
How did Belden Universal achieve $110,000 in annual savings?
The savings were split into two main areas: $60,000 was saved through improved labor utilization and machine uptime, while $50,000 was saved by deferring capital investments after Amper revealed hidden capacity in their existing machines.
What was the biggest benefit of Amper for Belden’s leadership team?
The primary benefit was the ability to forecast with precision. As GM Nick Sainati noted, knowing exactly where capacity exists allows the team to make confident decisions about when to add labor or equipment, rather than relying on guesswork.
How did Amper help Belden Universal avoid buying new machinery?
By monitoring real-time utilization, Belden discovered they had significantly more capacity than they realized. This allowed them to increase throughput on their current machines, deferring the need for a $50,000 investment in new equipment.
Can Amper help reduce overtime and labor costs?
Yes. Belden Universal used Amper data to align their labor scheduling with actual machine demand. This ensured they weren't overstaffed during slow periods and could optimize their workforce for maximum productivity, saving $60,000 annually.
How does real-time data improve customer on-time delivery?
With accurate capacity forecasting, Belden can provide customers with more reliable lead times. They know exactly how much work is in the pipeline and can adjust schedules proactively to ensure every job stays on track.
Is Amper a good fit for manufacturers focused on "Lean" operations?
Absolutely. Belden Universal’s success shows how Amper supports Lean manufacturing by identifying waste (idle machines and underutilized labor) and providing the data needed to eliminate it.