Client : Auto Component Manufacturer

Requirement : The manufacture of the three components.

Background : A large Auto Component Manufacturer contacted us to manufacture three major components in record time. These components were meant to be a part of a localization project.

Deliverables : The first two components, namely the cover and the nipple are extremely critical, deep drawn and formed parts used as part of a air suction valve device designed to reduce the emissions from two wheelers. The dimensional tolerances for the same are extremely tight as well as the problems encountered during the flow of material during the deep draw operation.

The second component is a similar deep drawn part which is extremely critical for fuel injection equipment used in 4 wheelers. This complete assembly is being currently supplied in a volume of over 50,000 assemblies a month to most of the leading 4wheeler manufacturers.

Challenge : Our customer offered us a choice to either develop the parts in a month or to refuse so that they could plan the imports. We accepted the challenge. We must add that our customer was equally supportive and confident that we would succeed. We decided to split our development team into two. One that would do the deep draw portion and the other that would do the forming portion of the component.

Result : the first two components were done in record time. After 20 days the teams matched their developments and at the end of the 30 th day we had an answer for our customer.

However, for the third component, we took almost 6 months to arrive at a final acceptable part that met all the drawing dimensions. We have to acknowledge the support and patience of our customer who threw us the challenge and had enough faith in us to allow us to achieve the desired results although it took almost 6 months