Project Overview
A major automotive OEM approached CoreLMould for high-volume production of complex dashboard components for a new vehicle platform. The project required exceptional precision, surface finish quality, and documented manufacturing processes.
Challenge
The primary challenges included:
- Tight Tolerances: ±0.05mm dimensional requirements for structural components
- Class A Surface: Flawless interior visible surfaces requiring SPI A-2 polish
- High Volume: 500,000 units annually with zero quality compromise
- Automotive Compliance: Full PPAP documentation and IATF 16949 requirements
- Material Specifications: UV-stabilized ABS/PPC blends meeting automotive interior standards
Solution
Our engineering team developed a comprehensive solution:
Mold Design
- Hardened steel molds (H13) with hot runner systems for optimal gate placement
- 8-cavity family mold design for production efficiency
- Integrated cooling channel optimization reducing cycle time to 45 seconds
- SPI A-2 polish on all Class A surfaces with texture matching
Process Engineering
- SPC implementation across all critical dimensions (Cpk �?.33)
- In-process inspection stations at every cavity
- Automated visual inspection system for surface defects
- Material traceability from raw material to finished part
Quality Assurance
- Full PPAP documentation package (PFMEA, control plans, MSA, process studies)
- CMM verification protocol for critical dimensions
- Inbound material verification against certificates of analysis
- Final inspection with automated optical measurement
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| First-Pass Yield | 98% | 99.7% |
| Cycle Time | 50 seconds | 45 seconds |
| Dimensional Cpk | �?.33 | 1.56 |
| Customer Escapes | <100 PPM | 0 PPM |
| Cost Reduction | Baseline | 20% |
Key Success Factors
- Early Supplier Involvement: DFM analysis during design phase identified 12 potential issues before tooling
- Robust Process Control: Real-time SPC monitoring with immediate feedback loops
- Continuous Improvement: Monthly process audits and capability studies
- Strong Documentation: Complete audit trail from raw material to delivery
Customer Testimonial
“CoreLMould demonstrated exceptional professionalism and technical expertise. Their PPAP documentation was comprehensive, and the production ramp-up was seamless. The quality consistency over 500,000 units speaks for itself.”
- Quality Director, Major Automotive OEM