Product rework requests are the last thing any manufacturing company wants to receive from clients. These corrections consume valuable time and resources and impact customer satisfaction and company reputation.
Yet Rapid Axis, a US-based custom component manufacturer, has turned this common industry challenge into a remarkable success story. In 2023, Rapid Axis maintained an exceptionally low RMA (Return Merchandise Authorization) rate of 1.3 percent, with merely 37 cases requiring rework out of 2,845 completed jobs.
This outstanding performance stems from a carefully crafted approach developed by founder and president Jared Probst, who has spent years refining the company’s processes. His formula combines three key components: a talented team, stringent quality standards, and open communication with clients throughout every project.
Expert Teams Drive Quality
The foundation of Rapid Axis’s success in minimizing rework lies in its team of skilled professionals. These experts have extensive experience from publicly traded companies and bring diverse insights and deep technical know-how to each project.
“Manufacturing excellence starts with people,” Probst explains. “Our team’s extensive experience allows them to anticipate potential issues before they arise and implement solutions proactively. When challenges occur during production, their expertise enables quick, effective problem-solving.”
This human touch is complemented by state-of-the-art technology to ensure precision in every component. Whether working with CNC machining services, sheet metal fabrication, injection molding, or 3D printing, the team’s understanding of each process helps maintain consistent quality across all projects.
Proprietary Standard Measures
At Rapid Axis, CNC machining services require precision in sizing, material selection, and geometric specifications. Its multi-tiered inspection process, supported by ISO 9001 Certification and ITAR Registration, begins with skilled fabricators who conduct initial evaluations. This includes measuring components, verifying features, and performing visual inspections of secondary operations to ensure the accuracy of prototype components before they undergo a detailed examination.
For clients seeking enhanced quality assurance, Rapid Axis provides Full First Article Inspection (FAI), using precision measurement tools, gauges, and micrometers to verify 100 percent of manually measurable dimensions. While following their standard FAI template, they readily accommodate client-specific templates during the Request for Quote (RFQ) process, demonstrating their commitment to customer needs.
Beyond individual inspections, Rapid Axis extends quality assurance to production volumes through Acceptable Quality Level (AQL) support and Coordinate Measuring Machine (CMM) inspection capabilities. This comprehensive approach, as Probst notes, gives their team a framework to catch potential issues early when corrections are more straightforward and more cost-effective, ensuring both prototypes and production runs meet exact specifications.
Clear Communication and Early Prevention
Rapid Axis emphasizes thorough communication with clients from the start of each project. Their quick-response quotation system provides pricing and manufacturability feedback within hours, helping identify potential issues before production begins.
According to Probst, the company maintains open dialogue throughout the manufacturing process to ensure specifications are clearly understood and met precisely. This approach prevents misunderstandings that lead to rework requirements later in the project lifecycle.
“The final say will always be the clients. We are all about understanding exactly what our clients need and delivering solutions that perfectly meet those needs,” Probst notes. “Clear communication from the start helps us achieve this goal consistently.”
Quality Control: An Ongoing Process
Rapid Axis’ impressive 1.3 percent RMA rate reflects its mastery of manufacturing challenges. Drawing from 25 years of industry experience across CNC machining, sheet metal fabrication, injection molding, and 3D printing, Probst emphasizes that excellence comes through consistency rather than pursuing perfection.
This philosophy shapes every aspect of their operation, from hiring skilled professionals to implementing robust quality control systems. While maintaining rigorous standards, the company stays adaptable, readily embracing new methodologies and technologies to enhance its processes.
“Manufacturing perfection is an ongoing journey,” Probst concludes. “By maintaining our focus on quality and continuous improvement, we help our clients achieve their goals more efficiently while building lasting partnerships based on trust and reliability.”
