Major U.S. Bank Conversion
Case Study 01
A top 5 major US bank purchased a large regional bank with branches in California and other western states.
Over 1,600 ATM products manufactured and installed on time
2x production output sustained over 5 months without capital expansion
Zero disruption to other Sterling ATM’s customers’ orders
Enabled a top 5 U.S. bank to launch a unified ATM network by Memorial Day 2023
Scope of the ATM Conversion
Over 600 ATMs needed to be converted to new bank branding with regulatory approval given in late 2022 and the conversion completed by Memorial Day 2023.
This included hundreds of ATM surrounds, toppers, enclosures and cabinets.
More than 200 locations needed to be temporarily branded. This included hundreds of ATM surrounds, toppers, enclosures and cabinets.
Unique Challenges
Sterling ATM was at plant capacity at the end of 2022 when the conversion orders needed to be scheduled and Sterling needed to more than double their capacity. Essentially, they needed to significantly increase their volume of units produced for this major US bank while at full capacity.
To stay organized and in lock step with the Bank during conversion, Sterling created a set of daily reporting that is still used to this day.
More than 200 locations needed to be temporarily branded. This included hundreds of ATM surrounds, toppers, enclosures and cabinets.
Solution
Sterling ATM turned to its sister division, Bean Trailer, a manufacturer of rugged off-road travel trailers. While operating in a different industry, the two businesses shared common assets in manufacturing space, production systems, and skilled labor
1. Shared Manufacturing Facilities (Sterling gave it the Beans!)
Sterling shut down the Bean Trailer line and leveraged its manufacturing facilities (Bean pods) to expand its production footprint. Bean’s production facilities were purposefully built to allow ATM to flex to produce ATM branding elements.
2. Skilled Labor Cross-Training
Personnel from the Bean Trailer fabrication, assembly, and quality teams are cross trained on ATM surround assembly and finishing techniques. By migrating over 25 additional workers from Bean’s crew, Sterling doubled its production shifts while maintaining a consistent quality standard.
1. Shared Manufacturing Facilities (Sterling gave it the Beans!)
3. Agile Manufacturing Systems
Using their experience as a winner of the Utah Manufacturers Association (UMA), Manufacturer of the Year, Sterling adapted Bean Trailer’s LEAN production methodologies to improve throughput. Standardized work cells and modular assembly processes borrowed from trailer production were reengineered for ATM surround manufacturing, increasing output efficiency by over 100%.
Conclusion
Sterling ATM’s success in supporting this massive conversion is a testament to the power of cross-divisional synergy. By harnessing the manufacturing strength and operational agility of the Bean Trailer division, Sterling demonstrated how shared resources across brands can drive innovation, speed, and reliability under pressure.
This project not only strengthened Sterling’s strategic relationship with the bank but also proved a replicable model for scaling quickly in high-stakes, time-sensitive environments.
Testimonial
Sterling ATM has been an invaluable partner to our team, consistently delivering innovative, high-quality solutions with precision and reliability. In 2022, during the acquisition of a large California-based bank, Sterling played a critical role in designing a temporary signage solution that not only met brand standards but was durable and refined enough to remain in place well beyond initial expectations with conversion Day 1 being pushed back.
They managed a 600 ATM conversion project entirely in-house with their trusted project managers, staying agile amid shifting timelines and high-volume demands. Whether it was holding inventory to accommodate delays or accelerating production to meet fast-tracked installation dates, Sterling ensured they were never the bottleneck.
Their coordination with our ATM manufacturer was seamless, aligning delivery schedules, assisting with warehousing logistics, and even helping us consolidate and organize joint inventories at rigger facilities in California.
Branding Disclaimer
Our banking partner has requested that their branding not be featured in this case study. As a result, logos and other brand identifiers have been omitted to respect their preferences while still showcasing our product solutions.