Since the start of our business relationship with the company Sodecia we have implemented 43 projects for leading automobile manufacturers. In practice, this means more than 25,963,583 surface finished parts. Project of surface finish for mass produced parts: End customer automobile producer FORD requires surface finish complying with high standards and norms. It involves a combination of two technological procedures: ● zinc electroplating according to standard FORD WSS-M1P85-B3● cataphoretic painting according to standard FORD WSS-M2P177-C3 Project of surface finish of special material: The requirement for coating of product Sodecia for AUDI was demanding in many respects. The product requires coating according to standard VW13750 Ofl x634 with minimum coating thickness of 35 microns. As this is a relatively large flat part, moreover made of the special material CR3-EG47/47-E-PO, coating in the required scope is technologically demanding. The preparation of the entire process required a large volume of sampling. Thanks to the experience of our experts, we discovered during the sampling that the product is susceptible to scratching. We fine-tuned the parameters and details of the entire process. We included a completely new product packaging approach in the process, and damage has no longer occurred. Completed, coated components reach the end customer at the assembly site in good order and with no faults caused during transport.
HANON, A DEVELOPER AND MANUFACTURER OF AIR CONDITIONING TECHNOLOGY COMPONENTS FOR THE AUTOMOTIVE INDUSTRY AND OUR LONG-TERM CUSTOMER, REQUESTS OUR SERIES AND PROTOTYPE PRINTED PARTS. Services which we offer and which are an essential part of any cooperation: During the initial request, we make a feasibility study and together with the design department we optimise the final shape of the prepared part. Processing of the required documentation and design of the production process according to customer requirements. Sampling before series production to check of the manufacturability of the part in the required quality. Description of the cooperation: Cooperation on a new project with the customer begins long before the call-off order itself is accepted for production, when a feasibility study and a capacity study are carried out. This ensures smooth delivery of the product in the quantity required by the customer. This corresponds to the preparation of the offer, including the possibility of further updates in the case of changes in the design or requirements. Sampling and documentation according to VDA and PPAP are a matter of course. We place great emphasis on the precise fulfilment of customer requirements and 100% quality control. We ensure this through 3D measurements, strength tests, corrosion resistance tests, surface quality tests and visual inspections of each part. It is a matter of course to meet delivery deadlines and ensure trouble-free deliveries, including the traceability of the process. Case study: Production of a sleeve for attaching air conditioning lines The finished part goes into the final product of the vehicle air conditioning system. A possible product failure could lead to malfunctions in the air conditioning circuit. Requirements for precise processing are indispensable. To ensure the quality and regularity of series deliveries for the customer, processes were optimised in the pre-production phase. Cooperation details: Cooperation started as early as during the construction of the part by the customer, when we eliminated the possible occurrence of cracks on the reinforcement edges during the jointly designed execution. Implementation of the documentation required for the production process, including an inventory of the technological flow, FMEA, OEE control plan and packaging regulations. Evaluation of the sampling and assurance of the required quality through the PSW (Part Submission Warrant) document. Ensuring the quality and supply of raw materials, semi-finished products, cooperation, process tools and measuring equipment. Pressing was carried out on a crank press with feed and straightening line using a customised process tool. Ensuring the required accuracy of the product, including checking the grip strength when assembling the sleeve. Removal of sharp edges and burrs from the part to ensure safety and to comply with the requirements of the standard for surface treatment according to automotive sector standards. Protection of the product with a cataphoretic coating, which gives the raw product excellent anticorrosive properties in spite of the minimal layer thickness. This is proven by corrosion resistance tests. Final assembly of the soft component that is in direct contact with the air conditioning pipe. Before final delivery of the part, final quality control of the output and an evaluation of the repeatability of the process is also carried out. We return to the input operations and introduce the documentation required for the process. The customer then appreciates the careful evaluation of the sampling and quality assurance, which is provided by the PSW (Part Submission Warrant) document.
A DEMANDING JUST IN SEQUENCE DELIVERY REQUIREMENT WAS MADE BY A KOREAN CAR MANUFACTURER. THE TASK OF DELIVERING AN AVERAGE OF 550 SETS PER DAY WHEN ASSEMBLING THE STEEL STRUCTURES OF PASSENGER CAR SEATS WAS FULFILLED BY LAKUM FROM 2011 TO 2014 TO THE FULL SATISFACTION OF THE CUSTOMER. Objectives and details of cooperation High flexibility in design and continuous adaptation of requirements. Design that exceeds the required capacity of 550 sets per day. At the peak of production, up to 900 sets per day were achieved. Adaptation of production to the indicated background in the company, which for the whole project amounted to 1,000 m2. In just two months, our team at Lakum-AP was able to build a new assembly line, train the operators and deliver this key component directly to the customer's assembly line. In record time we managed not only to meet the customer's requirements for a relatively complex production programme, but also to exceed expectations for the required production capacity.
