65%

Reduction in manufacturing lead time

40+

Kaizen events completed since implementation

10-15

Operations automatically routed per Custom Seating System order

THE COMPANY

Stealth Products manufactures highly customizable wheelchair seating and mobility components used by customers with complex medical needs. Their Custom Seating System requires precise routing, multi-stage operations, and flawless communication between sales, engineering, and production — making accuracy and coordination essential as demand grows.

THE CHALLENGE

Managing Stealth’s Custom Seating System involved 10–15 operations per product and millions of possible configuration combinations. Their manual processes couldn’t keep up, leading to delays, rework, and department misalignment.

Key challenges included:

• Manual routing decisions for products requiring 10–15 different operations

• No reliable way for customer service to confirm whether selections were manufacturable

• Frequent errors caused by miscommunication between sales, engineering, and production

• Limited visibility: orders had to be physically tracked across four separate buildings

• Lack of shared understanding of product offerings across departments

• Extremely long CSR training times due to complex product knowledge requirements

THE SOLUTION

Stealth implemented a purpose-built Wheelhouse order entry and dynamic routing system designed to support their highly customizable product line.

Key improvements included:

• Automated routing that determines the correct 10–15 operations based on customer selections

• Structured order entry with built-in compatibility checking

• Unified product rules that support clear, cross-team communication

• Real-time production tracking with QR-code scanning across all facilities

• One shared system connecting sales, engineering, and production

THE RESULTS

65%

Reduction in Manufacturing Lead Time (from 11.5 days to 4 days)

40+

Kaizen Improvements Completed Since Implementation

10-15

Operations Automatically Routed Per Custom Seating System Order

ADDITIONAL OUTCOMES

Lead Time Reduction

Faster production cycles with fewer bottlenecks.

Training Revolution

CSR training time dropped from “indefinite” to hours.

Team Alignment

Shared rules eliminated cross-department confusion.

Routing Automation

No more manual routing decisions for complex products.

Error Prevention

Compatibility issues stopped before reaching production.

Knowledge Capture

One-time fixes improve every future order.

“[Wheelhouse] is just going to make your life easier.”

Willy D.

Manufacturing Engineer, Stealth Products

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Leggero

Learn how we implemented a comprehensive order entry and routing system specifically designed for Stealth Products’ Custom Seating System product line.