1. Power Tools of the Next Generation
Located in Nanjing, China, our customer is a company that excels in the integration of research and development, manufacturing, and sales of power tools and smart outdoor garden equipment. Their dedication and expertise have earned them numerous honors and recognitions, including the titles of a national green factory and a national industrial design center.
To boost the capability of one of their well-known power tools, our engineering team supported their R&D department in Expert Assortment Analysis and Expert Teardown projects. Throughout this collaborative process, thread-forming screws and self-tapping screws were used extensively on the product shell.
The Challenges: Complex Processes
- Multiple types of products to manage
- Complex assembly process in production
- High risk of fastener failure in the whole machine rework, such as cam-out
Our Solutions: Engineering Expertise and Superior Fasteners
We increase awareness of the problem, we held a technical seminar to train their engineers in focusing on improving design efficiency and reducing risks by utilizing thread-forming screws. We provided technical clarification on the superior performance of ecosyn® plast screws compared to self-tapping screws, which effectively resolved product failures.
Customer Benefits
Our engineering services have significantly increased customer satisfaction and opened doors to special opportunities. The use of special self-tapping screws, specifically designed for plastic parts like ecosyn® plast, has resulted in a notable 20% reduction in rework. Additionally, due to Bossard's advanced solutions, the customer has achieved an impressive 25% decrease in the total cost of the assembly process each year.
2. Productivity Improvements with Our Teardown Services
Our second customer, a prominent electrical and electronic equipment manufacturer in China, specializes in producing a wide range of products, including high-voltage devices, low-voltage devices, transformers, switchboards, PLCs, inverters, and automation devices.
They sought to enhance their production efficiency and optimize fastening applications with the assistance of our Expert Teardown services.
The Challenges: Inefficiencies
- Inefficient nameplate attachment
- Low efficiency caused by the use of anti-galling grease applied to stainless steel fasteners
- Reduced efficiency due to the application of thread anti-loosening glue on the screws
Our Solution: Targeted Improvements
To address these challenges, we advised the customer to implement the following actions:
- Consider using speed rivets instead of semi-screws for faster installation
- Replacing Loctite-LB 8150 with Everlube 620C as a pre-lubricant alternative
- Utilizing pre-coated patches as a convenient and reliable sealing alternative to Loctite-243
Customer Benefits
As a result of our recommendations, our customer was able to overcome the stainless steel fastener galling issues. Additionally, the thread-locking glue is applied more evenly, resulting in a good anti-loosening effect. Production efficiency improved by 30% with 51% decrease in costs. This translates to 4,945 working hours saved annually – which is equivalent to 2.4 headcounts.
3. Better Quality Printers with Assembly Technology Expert
The third customer is a global leader in providing safety identification and compliance solutions. Their product portfolio includes portable, desktop, and industrial printers, along with versatile barcode scanners for effective tracking applications. In Malaysia, their primary focus lies in providing exceptional support for key products, specifically labels and printers.
To maximize customer success and minimize product life cycle costs, it is crucial to prioritize the selection of optimal fastening solutions. By carefully considering factors such as cost and safety, we could effectively showcase the value of our Assembly Technology Expert services.
The Challenge: Switching from Imperial to Metric Fasteners
To ensure economical part costs, it is evident that the use of imperial size screws may not be the most cost-effective approach. In light of this, we proposed a transition from imperial to metric size screws. This transition will enable every site to seamlessly make the switch, minimizing any risks associated with secure joint integrity during the partial change.
Our Solution: Support and Alternative Fasteners
- Switch from imperial to metric size screws for future support across all sites to improve cost-effectiveness
- We recommend the use of ecosyn® fix as a replacement for conventional screws with washers
- We proposed fan mount rivets as an alternative to conventional screws and nuts
Customer Benefits
Optimizing the fastening system involved replacing 30 imperial size screws with 22 metric size screws. This resulted in a significant 21% annual process time savings, enhancing overall efficiency.
4. Collaboration Towards a Better, Leaner Product
This Korean customer is an electrical manufacturer that produces high-voltage devices, low-voltage devices, transformers, switchboards, PLCs, inverters, and automation devices. With the highest market share in the Korean circuit breaker industry, this manufacturer has established a remarkable sales record, reflecting their strong presence and success in the market.
By collaborating with our R&D team, the customer was presented with a range of our engineering services, designed to enhance productivity and achieve cost savings. As a result of this engagement and an Expert Teardown, the customer was able to identify areas in their current circuit breaker model that could benefit from improvement.
The Challenge: Identifying Optimization Potential
We proposed three solutions based on a TCO report. These solutions encompass eliminating the Loctite application line, optimizing machining parts, and providing guidance on the optimal boss design for the integration of the new spiral cutting screw into vibration testing. With the implementation of Bossard's Expert Design, our customers gain the opportunity to significantly enhance the quality of their end products in a lasting manner. This comprehensive service offers valuable recommendations on materials, assembly conditions, and prototyping, empowering customers to achieve improved product outcomes.
Our Solution: Engineering Training and Fastener Improvements
Through frequent visits and engineering interactions, we gained customer trust and conducted a technical seminar to train their engineers. To enhance design efficiency and minimize risks, we implemented thread-forming screws and clarified the superior performance of ecosyn® plast compared to self-tapping screws, resolving product failures effectively.
Customer Benefits
By eliminating the requirement for Loctite auto-apply and mitigating issues related to loosening, the customer enjoys a substantial 35% reduction in Total Cost of Ownership (TCO).
Assembly Optimization
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