Case Studies No 1
AUTOMOTIVE SEGMENT (DIE CASTING)
SITUATION
The customer has just won a project with one of the major Automotive Companies yet facing a huge challenge to maintain a health margin.
CHALLENGE
SourcAsia go a chance to look at the details of the part to recommend a more cost competitive part and source with our engineering know-how and long experience in the Asia market
The part was currently machined out of a full metal bar with a lot of waste. Further the part has a few wings (clinching points) which in additional were difficult and costly to machine out. – The plating requirement was Zinc-Nickel (black) one more expensive piece to the entire part
The part was currently machined out of a full metal bar with a lot of waste. Further the part has a few wings (clinching points) which in additional were difficult and costly to machine out. – The plating requirement was Zinc-Nickel (black) one more expensive piece to the entire part
ACTION
SourcAsia closely worked with the customer on a number of suggestions
a) Recommended to change from “machining” to Zinc Die-Cast the part as the volume were sufficient – easy to form out the wings and other more complex features of the items – shorter cycle time – higher production output
b) Recommended to move away from Zinc-Nickel and use on Black-Zinc coating which was sufficient looking at the usage and environment exposed
a) Recommended to change from “machining” to Zinc Die-Cast the part as the volume were sufficient – easy to form out the wings and other more complex features of the items – shorter cycle time – higher production output
b) Recommended to move away from Zinc-Nickel and use on Black-Zinc coating which was sufficient looking at the usage and environment exposed
RESULT
The part was thoroughly test by the Automotive Company and approved with recommendation of using Zinc Die-Cast and the Zinc-Black coating.
Although there was an initial tooling cost for the Die-Casted part, the part itself resulted to a 35-40% lower in cost with the tooling amortized over 2 years.
Although there was an initial tooling cost for the Die-Casted part, the part itself resulted to a 35-40% lower in cost with the tooling amortized over 2 years.
Case Studies No 2
MEDICAL SEGMENT
SITUATION
A pioneer in the life science industry producing complex pipetting system uses metal harden pins pressed into plastic base plates. Each of the plate has from 96 to 384 such pins pressed into the plate – those plates are dispensable and often replaced once the pins where not that sharp anymore
CHALLENGE
One of the critical points (challenge) was the material of the pin plus to produce a super sharp tip after the hardening process so to ensure breaking of the plastic cover of the pipetting system
ACTION
SourcAsia closely worked with the customer on a number of suggestions
a) The material was not commonly used in Asia – analysed the material and made a number of alternative suggestions with equal strength and properties
b) Proposed to make samples for “square parts” as this would make the part stronger in the TIP area with 4 sides instead of round
c) Got approval to work with the company eventually pressing the pins into the plastic to understand there challenges and requirement
a) The material was not commonly used in Asia – analysed the material and made a number of alternative suggestions with equal strength and properties
b) Proposed to make samples for “square parts” as this would make the part stronger in the TIP area with 4 sides instead of round
c) Got approval to work with the company eventually pressing the pins into the plastic to understand there challenges and requirement
RESULT
With all the points taken in consideration, SourcAsia made a number of samples with the proposed materials and shapes (round, square) including taken in consideration the requirement from the plastic moulding company to arrange special chamfer at the end of the pin for easy guidance and press into the material
The pin was approved an resulted in a 50% cost saving for the customer and improved design/application
The pin was approved an resulted in a 50% cost saving for the customer and improved design/application
