Project Overview
An automotive electronics supplier required complete manufacturing of electronic control modules. The project demanded IATF 16949 certification, housing production, PCB integration, and final functional testing.
Challenge
The primary challenges included:
- IATF Certification: Automotive quality system requirements
- Complete Solution: Housing, PCB assembly, and final testing
- Environmental Protection: IP67 sealing for under-hood use
- Functional Testing: 100% electrical and functional verification
- Cost Efficiency: Lower cost than multi-supplier approach
Solution
Our engineering team developed a comprehensive solution:
Manufacturing Integration
- In-house housing tooling and molding
- PCB assembly with automated SMT line
- Potting process for environmental protection
- Final assembly and functional testing
Quality Systems
- IATF 16949 certified processes
- PPAP documentation package
- SPC on critical dimensions and electrical parameters
- Traceability from raw materials to finished modules
Testing Excellence
- 100% electrical continuity testing
- Functional testing simulating vehicle operation
- Leak testing for IP67 verification
- Thermal cycling validation
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 500K units | 1M+ units |
| Field Failures | <100 PPM | 0 PPM |
| Cost Reduction | 15% | 25% |
| PPAP Status | Approved | Approved (First Pass) |
| Test Coverage | 95% | 100% |
Key Success Factors
- Vertical Integration: Complete manufacturing under one roof
- Automotive Expertise: IATF 16949 systems and PPAP experience
- Testing Rigor: 100% functional testing ensuring product quality
- Cost Efficiency: Integrated approach delivering significant savings
Customer Testimonial
“CoreLMould’s one-stop manufacturing transformed our supply chain. They produce complete modules from housing to final test, reducing our cost by 25% with zero quality issues. True manufacturing partner.”
- Operations Director, Automotive Electronics Supplier