Metal fabricator upgrades quality, cuts lead times for prisoner restraint system

Developed by Police Innovations LLC, two Supplemental Prisoner Adjustable Restraint (SPAR) chairs are nearly ready for shipment.

While most people sleep safely at home each night, many police officers toil on the night shift, charged with apprehending, processing, and transporting dangerous criminals. This high-risk endeavor puts police officers in harm's way as standard operating procedure, and it's not uncommon for serious injuries to occur when prisoners get out of control. The situation becomes even more challenging in rural areas, where police departments already struggle with staffing and quick access to backup support.

Matthew Planer, formerly a patrol sergeant for a Reading, Pa., suburb, was working as a shift supervisor when a prisoner kicked out the window from the back of a police cruiser, following another prisoner who had laid waste to a local police station in a violent tirade. That led Planer to devise a new way to keep unruly prisoners restrained. He sketched an idea for a restraining chair to hold prisoners in place and keep police officers safe at a distance.

Planer founded Police Innovations LLC, and within a few years business began to boom. Made from a substantial amount of fabricated tubing, the restraint resembles the over-the-shoulders type of restraint system common to roller coasters. Later patented as SPAR, the Supplemental Prisoner Adjustable Restraint, this clever restraining device has become a highly prized addition at many police stations, correctional facilities, courtrooms, and other places where potentially violent prisoners need to be restrained continuously.

Unfortunately, problems with manufacturing were restraining Planer's plans for growth. The quality of the dozens of fabricated metal parts was inconsistent, the assembly lacked attention to detail, and the slow pace of production required up to 16 weeks from order to delivery. Furthermore, an order leaving for delivery arrived damaged nearly 50% of the time because of haphazard packaging. Replacing damaged parts or entire units after already taking 16 weeks in process was devastating, and the metal contractor didn't seem to care, according to Planer.

He soon began searching for a better manufacturing partner.

A New Beginning with a New Metal Fabricator

After reviewing a number of metal fabricators in his area, Planer turned to TAB Industries. Based in Reading, the family-owned company offers precision laser cutting, metal fabrication, welding, stamping, CNC machining, assembly, design engineering, warehousing, and associated services from its 44,000-square foot facility. TAB uses a slate of new machinery and equipment such as a 3,300-W BesCutter fiber optic laser cutting machine, a U.S. Industrial Machinery hydraulic CNC brake press, and a series of gas metal arc welding and gas tungsten arc welding workstations.

Using a turnkey approach, TAB manages the entire production process, from order to delivery, to help companies like Police Innovations focus on their core areas of expertise.

From Design Review to Shipping. “TAB's design engineers immediately redesigned a number of parts for much faster, more efficient manufacturing,” said Planer. “I was very impressed. They're a game-changer, and sometimes I can't believe how they've done so well for us.”

TAB manufactures about 25 restraint devices each month on deadline. The company sources and stores the materials and components, produces the myriad metal parts; handles the welding and powder coating; assembles the entire unit; performs testing and inspections; and then palletizes, secures, and packages the unit for safe transport. With several decades of global logistics experience, TAB even handles the delivery process to the customer.

Wrapped and ready for shipping, the Supplemental Prisoner Adjustable Restraint (SPAR) chairs are secured to pallets by shrink-wrap applied by an automated system, TAB Industries’ Tornado Wrapper. Visit https://www.tabwrapper.com/videos to see the machine in action.

“The quality is superb, their skilled workers really care about putting together a quality product for us,” said Planer.

To ensure each order arrives in the same condition as when it leaves the facility, TAB uses its signature orbital wrapping machine, the TAB Wrapper Tornado. The patent-pending pallet wrapping machine automatically wraps stretch wrap 360 degrees around the entire restraint chair and under the pallet to create a secure, unitized load that prevents the chair from shifting in transit.

“When I first saw the TAB Wrapper, it blew my mind. It's amazing,” said Planer. “It's a huge relief having this level of protection during shipping and storage.”

Since entrusting TAB with manufacturing, parts consistently meet quality specifications, lead times have been cut by 400%—from up to 16 weeks to four weeks or less—and not a single order has been damaged during transport or rejected upon arrival. With product quality and production speed issues resolved, Planer acquired a distribution company, began exhibiting at industry tradeshows, and sales have increased dramatically. TAB has since helped design a mobile version of the restraint system on casters that quickly outsold the original, stationary model.

Customizing When Necessary. “This growth is only possible because of TAB Industries,” said Planer. “Now I know that no matter how many orders we get, TAB will deliver on time, every time, and make us look fantastic.” As if testing his confidence in TAB, Planer recently received a substantial order from a law enforcement agency in Spain. However, the agency required the restraint chairs to be modified for mounting within transport vehicles.

TAB engineers worked directly with the Spanish agency and developed new parts and components to fit the specifications. Since wooden pallets are not allowed when shipping to Spain to comply with invasive pest control protocols, TAB engineers designed a custom metal racking system for placement inside the shipping container. This approach keeps each of the 24 restraint chairs securely in place throughout the voyage.

“I didn't have a lot of experience dealing with overseas logistics, but Tom [Brizek, president of TAB] does,” said Planer. “The process could've been a nightmare, but it's been smooth, and we're actually ahead of schedule.”

Unrestrained Growth

With each order and delivery, the SPAR restraint chair becomes more visible within law enforcement circles.

“It's very common for an officer picking up a prisoner held in our restraint chair to show it to a supervisor or colleague and request it for his or her agency,” said Planer. As word of mouth spreads and repeat orders continue, Planer sees no real limits to the potential for growth.

“This is a safety issue, and that affects every law enforcement agency on the planet,” said Planer. “But this business would not have been successful without TAB Industries. The attention to detail, the high level of expertise, and their willingness to work with us at every turn have been crucial for our growth.”