Case Study: Automotive

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Process: Stamping Transfer

Quality Improvement and Cost Savings

Challenge

Transfer a high risk Ignition Terminal Production Line for a major automotive OEM. A recent quality spill had jeopardized the business for our customer. This program involved the complete transfer of stamping presses, stamping dies, and related support equipment.

Solution

Prior to the transfer, our select team of mechanical and electrical engineers, tooling craftsmen and experienced production and quality personnel studied the existing process and discovered possible production improvements while conducting a risk analysis. This analysis ensured that our people not only had a sound process for manufacturing the terminal but an expanded quality program with 100% inline vision inspection.

Result

Working in concert with our customer’s quality, engineering, and purchasing personnel, Oberg delivered fully PPAP’d (Production Parts Approval Processed) production ready assemblies in less than three weeks. Our process improvements enabled our skilled press operators and technicians to increase production volumes by 25% and to date, over 200,000,000 assemblies have been supplied with a PPM of .06. Cost-down targets were achieved with a combination of our technology and personnel as well as leveraging our corporate purchasing resources.