Success Stories
With our tailored fastening solutions and expertise in lightweight materials, we are boosting the performance of electric vehicles. Supply chain optimization ensures reliable fastener delivery, while cutting costs and meeting production goals.
The customer: a global provider of stored energy solutions for the transportation and industrial markets. Their products and services include batteries and battery systems for vehicles, standby power applications, and motive power applications. They specialize in advanced battery technology solutions, particularly lithium-ion batteries for industrial applications.
R&D engagement at the design stage involves collaborating with the research and development team to specify the necessary requirements for a product. This process can help to ensure that the product meets the desired specifications and performance standards before it is manufactured.
Our customer had limited knowledge of fastener selection for EV battery applications. Therefore, they greatly benefitted from our expertise in this area. Selecting a partner with the necessary know-how in EV fastening technology is crucial to ensure that the fasteners selected are appropriate for the specific requirements of EV batteries, which depend on factors such as the size and weight of the battery, the materials used in the battery casing, and the operating conditions of the battery.
Despite COVID-19 restrictions, we conducted a virtual product teardown to find more innovative solutions for our customer. Thus, even under those special circumstances, we were able to help – leveraging remote collaboration tools and technology support such as video conferencing, and remote access to testing equipment.
Our solution for this customer was standardization of fasteners, material, and plating. They will use base materials that match the mating materials to avoid corrosion and ensure a longer service life for the fasteners, utilizing stainless steel for corrosion protection where needed. This standardization reduces storage efforts, streamlines inventory, and lowers costs. Overall, the company has saved 945 hours of time.
This customer specializes in the production of electric scooters and bikes, with a focus on providing affordable, high-quality EVs for the Indian market. Their products are designed and developed in-house, with their manufacturing facility located in Goa, India.
The customer requested our support in selecting fasteners for their new model.
The customer was facing pain points and challenges with their initial lot of the model. They received market feedback indicating quality issues such as rusting, boss rupturing, cracks in the plastic, and loosening due to vibration. We came in to support them in improving their product.
To get to the root of the problem, we conducted a detailed analysis of the fastening elements used, as well as a total cost of ownership (TCO) analysis through a professional expert teardown. In this process, we disassembled the customer's product into its single parts and analyzed the interface complexity of each component. Our technical specialists examined every inch of the product to understand its functionality and to identify potential cost savings, as well as opportunities to improve the quality and reliability of the model.
Based on our analysis, we suggested reducing plating types to two, eliminating the rejection of mating parts, preventing vibration loosening, and introducing a special collar to the steering column assembly. These improvements do not only reduce risk and improve product safety, but also save 158 assembly hours.
This customer is a comprehensive manufacturer specializing in developing and producing various types of internal combustion engine-powered equipment and vehicles. They offer generating sets, agricultural machinery, light-duty power units, and motorcycles. They also venture into emerging businesses that leverage their internal combustion engine technology expertise.
The company has established stable strategic partnerships with globally renowned enterprises. They operate as a world-class power system manufacturer with a presence in over 100 countries and regions worldwide.
Automated assembly lines for motorcycle engines have a high requirement for the stability of the friction coefficient in fasteners. In joint venture projects, the R&D team is responsible for the evaluation and localization of parts. Our customer’s engineers lacked experience in fastener application and were in need of a reliable supplier to provide engineering support and quality parts.
We demonstrated our value-added services through technical seminars and actions, training the customer in improving design efficiency, reducing risks, and providing daily engineering support to address product failures and improve design and process flow. Our coefficient of friction tests showcased our engineering expertise, which are highly appreciated by our customers.
With our technical support and product solutions, we have successfully improved the stability, safety, and production efficiency of our customer's products. Our assembly technology expertise allowed us to optimize fastener design and thus achieve substantial cost reductions for our customer.