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A smooth and error-free production process is crucial. EVOMOTIV the customer in improving the first-run rate through a design change in the series.
Project Details
Initial situation:
An unstable camshaft adjuster system caused failures during the assembly process and also in the field. The return spring repeatedly jumped out of its mount and caused the system to fail. The first run rate during the assembly process was not good and the design had to be changed to improve the robustness of the system.
Project assignment:
To make a design change, the steps of the manufacturing process must be adapted, implemented and validated. This requires a change to the assembly system. The change must be supervised and the implementation must be ensured with minimal disruption. The adaptation takes place in parallel and must cause as little downtime as possible.
Implementation:
As part of the industrial engineering, the new manufacturing process was defined and developed with the special machine manufacturer. The changes were then implemented constructively and the new manufacturing steps were integrated into the existing system.
Solution:
The design change was initiated by Industrial Engineering. The way the return spring was attached was changed and validated through intensive test series. The design change also required some assembly steps to be changed: the joining process of the return spring was revised. Since the change, there have been no more field failures and the first-run rate of the assembly process has improved significantly.
An unstable camshaft adjuster system caused failures during the assembly process and also in the field. The return spring repeatedly jumped out of its mount and caused the system to fail. The first run rate during the assembly process was not good and the design had to be changed to improve the robustness of the system.
Project assignment:
To make a design change, the steps of the manufacturing process must be adapted, implemented and validated. This requires a change to the assembly system. The change must be supervised and the implementation must be ensured with minimal disruption. The adaptation takes place in parallel and must cause as little downtime as possible.
Implementation:
As part of the industrial engineering, the new manufacturing process was defined and developed with the special machine manufacturer. The changes were then implemented constructively and the new manufacturing steps were integrated into the existing system.
Solution:
The design change was initiated by Industrial Engineering. The way the return spring was attached was changed and validated through intensive test series. The design change also required some assembly steps to be changed: the joining process of the return spring was revised. Since the change, there have been no more field failures and the first-run rate of the assembly process has improved significantly.
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