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      1. Metal One group Company

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        Case Studies

        Proven quality services - Stories around the world

        Solving Assembly Line Failures and Subsequent Warranty Issues

        North America

        Industry: Automotive OEM
        Regions: North America, South America, Europe, South Asia
        Plant Size: Over 5 million vehicles per year
        Nifast Partnership: since 1992 (5 million USD worth of components per year)

        Customer Issue: Assembly line failures and subsequent warranty

        An automotive OEM customer experienced assembly line failures and subsequent warranty issues with a spring-activated door assembly that would separate, and/or fail to function as designed. Nifast Corporation was contacted and invited to visit the customer’s assembly line for a first-hand view of the application.

        Survey Result: Thread deformation and torsional failure due to inferior fastener design

        On-line observation of fastener application, by Nifast and OEM personnel, determined that tapping screws were not fully seating, due to thread deformation, recess cam-out, or torsional failure during installation. As a result, a mechanical feature of the plastic component, being attached to an aluminum base, was compromised due to insufficient contact with the base, and subsequent interference with a latching mechanism.

        Nifast’s analysis showed that an inferior fastener design (selected from a standard parts book) and less-than-optimal pilot-hole size contributed to excessive thread engagement, high drive torque, and a low failure/drive ratio; further, making the application sensitive to on-line variation. Changing the cored pilot-hole diameter was not an immediate option due to production needs and cost of inventory.

        Our Solution: Testing and installation of high-performance tri-lobular thread-rolling screw

        A high-performance tri-lobular thread-rolling screw was recommended by Nifast, and successfully tested by customer in the application. The tri-lobular screw’s three points of contact during thread-rolling (into nut-member) reduced radial stress and subsequently, installation torque; allowing fasteners to fully seat without incident.

        Further, as the nut-member material relaxes around the tri-lobular shape, the combination becomes a natural locking feature; improving back-out resistance.

        Outcome: Increased assembly productivity and reduced costs

        Customer’s problems related to seating of fasteners went away. Nifast is continuing to supply tri-lobular fasteners for this application, while the customer is enjoying increased productivity and reduced costs.

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        Solving Inventory Management and High Product Cost Problem

        India

        Industry: Automotive OEM
        Regions: India
        Plant Size: 245 million line items per year
        Nifast Partnership: since 2008 (762 million INR worth of components per year)

        Customer Issue: Inventory Mis-management and high product cost

        An automotive OEM customer experienced high product cost due to mis-management of Inventory, long term inventory storage cost, improper projections of imported material resulting assembly line failures . Nifast India was contacted and invited to visit the customer’s plant for a first-hand view of the situation.

        Survey Result: Variance in customer forecast and failure of inventory management system due to lack of expertise in dealing with fasteners.

        On observation of planning and forecasting system, by Nifast and OEM personnel, determined that there is big variance in the forecasting system of the OEM and due to that their inventory levels have gone up resulting in the high inventory storage cost and impacting the cash flow of the company due to high value of the imported product. Customer was also facing problem in timely importing the required material due to long transit time and custom clearance issues resulting in line stoppage problem in case of non-availability of the imported material on scheduled date.

        Our Solution: Strategic alliance for cost reduction and JIT delivery by proper Inventory Management

        Nifast India provided the complete warehousing solution to the customer with just in time delivery facility to the customer. Simultaneously it was recommended by Nifast India to localize the fasteners with some local manufacturer by entering technical know how agreement with some expert Japanese manufacturer to reduce the product cost of the final product. Due to the use of imported fasteners the cost of the final product was very high and customer was not able to compete with its competitors who were holding the major share of the Indian market.

        Outcome: Increased assembly productivity and reduced costs

        Customer’s problems related to inventory management of fasteners went away. Nifast is supplying almost 90% of fasteners by following just in time delivery system and almost 50% of the fasteners have already been localized resulting in the drastic decrease in the product cost and the customer is enjoying increased productivity and reduced costs.

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