Automotive - Production Emergency
In the highly competitive automotive industry, suppliers are continuously seeking ways to improve their products and customer service. We were called by a supplier when a product development problem was identified at product launch.
The components of the instrument panels were generating noise from the speedometer cable. We were given the assignment of producing 40,000 custom plastic washers to solve the problem. The only catch was the due date - two days. That's about 14 washers per minute for two straight days around-the-clock.
We "turned" the washers from nylon bar stock the first day. Then, on day two, we developed a punch and die, making the parts from sheet stock in an effort to reduce cost. Our customer successfully installed the parts and prevented the production line from coming to a complete stop.