Project Overview
A Tier-1 automotive supplier required complete assembly of interior trim modules. The project demanded integration of multiple molded components, ultrasonic welding, hardware insertion, and IATF 16949 certified assembly processes.
Challenge
The primary challenges included:
- Multiple Components: Integration of 8+ molded parts per assembly
- Ultrasonic Welding: Strong, consistent welds for structural integrity
- Hardware Insertion: Precise placement of clips, screws, and inserts
- IATF Certification: Automotive quality system requirements
- Cost Efficiency: Lower cost than customer’s current assembly method
Solution
Our engineering team developed a comprehensive solution:
Assembly Process
- Dedicated assembly cell with error-proofing systems
- Ultrasonic welding with automated parameter monitoring
- Pneumatic presses for consistent insert installation
- Vision system for component verification
Quality Systems
- IATF 16949 certified assembly processes
- Weld strength testing on scheduled frequency
- Dimensional verification of assembled modules
- Functional testing of all moving features
Production Excellence
- Standardized work instructions with visual aids
- Operator certification and training program
- Traceability from components to finished assemblies
- Packaging designed for assembly protection
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 200K units | 500K+ units |
| Weld Strength | 80% material | 95% material |
| Quality Escapes | <50 PPM | 0 PPM |
| Cost Reduction | 20% | 30% |
| PPAP Status | Approved | Approved (First Pass) |
Key Success Factors
- Assembly Expertise: Integrated manufacturing and assembly under one roof
- Automation: Error-proofing systems preventing assembly mistakes
- Quality Focus: IATF 16949 systems ensuring zero defects
- Cost Efficiency: Efficient processes delivering significant savings
Customer Testimonial
“CoreLMould’s assembly capabilities transformed our supply chain. They deliver complete modules ready for installation, reducing our labor by 30% with zero quality issues. True one-stop manufacturing.”
- Manufacturing Director, Tier-1 Automotive Supplier