Cut Lead Times from 10 Months to 0—Now That’s Smart Manufacturing
“I wouldn’t tell my friends about Colewell—because I want them all to myself.”
– Mike Boyle / VP of Manufacturing & Logistics, Interpower
Challenge:
When you're sitting on a 45-week lead time and watching customer orders stack up, something's got to give. For Interpower, a global power cord and component manufacturer, that something was an overseas supply chain. The solution? Bring the process home—and bring in Colewell Automation.
This is the story of how one forward-thinking Iowa manufacturer tackled vertical integration head-on. Their product? A field-rewireable plug—a deceptively compact component used in everything from medical equipment to industrial testing machinery. It’s globally standardized, built to tight tolerances, and essential across geographies.
But bringing it in-house meant creating a completely new automated process. That’s when Colewell came in.
“We used to buy this part from a company in Switzerland, and it was manufactured in India,” says Mike Boyle, VP of Manufacturing & Logistics. “It was just one of those things we felt we could own. We’re big into vertical integration, and this was a prime candidate.”
– Mike Boyle / VP of Manufacturing & Logistics, Interpower
Solution:
Mike first heard of Colewell through an automation component supplier. “I just started asking around. Who actually builds automation systems nearby? Colewell kept coming up.”
Early collaboration kicked off with Steven Coleman. Mike handed over a prototype and asked: “Is there anything in our design that would make automation harder? Let’s get it right from the beginning.”
That conversation sparked a tight partnership between Interpower's engineering team and Colewell’s designers. Even when budgets forced a pivot, the Colewell team stayed nimble. “Steven just pulled up the CAD model and said, ‘What about this?’ Fifteen minutes later, we were back on track.”
Colewell delivered a fully custom system, built in-house and programmed from scratch. Key features included:
Servo-driven index tables for precision
Weber screw feeders for fast, consistent insertions
Heated insert presses for spiral threads
Bowl feeders with escapements for gentle handling
Dual Keyence vision systems to verify placement and quality
“The camera system was key,” Steven explains. “It checks before and after each cycle to make sure every part is perfect.”
Even with complex functions—angled insertions, strain reliefs, and tight handling—the robot handled an entire production line with total accuracy.
“Once we handed it off, our people picked it up fast. Within an hour, they were comfortable - They’re only 25 miles away. Setup and training were a breeze.”
– Mike Boyle / VP of Manufacturing & Logistics, Interpower
Results:
Interpower saw immediate and measurable improvements:
Lead times cut from 45 weeks to same-day shipping
Complete control of production, scheduling, and inventory
Full reshoring of the product, using all North American components
“This changed our supply chain completely,” Mike says. “We build them here, stock them here, and ship them the same day.”
When asked if he’d recommend Colewell, Mike jokes: “Honestly, I wouldn’t tell my friends—because I want them all to myself. Like your secret hunting spot.”
Colewell’s Steven Coleman adds, “This was one of the most intricate systems we’ve ever done—and it opened the door for even more complex builds. Once you prove it can be done, the doors just keep opening.”