A leading manufacturer of diesel fuel filters risked delays on a production ramp carrying a significant penalty from their OEM automotive customer. They had tried second sourcing a diaphragm component, only to learn that the factory they selected was unable to achieve more than 25% efficiency of their production tool. Only 4 of 16 cavities were producing satisfactory parts.
Darcoid was asked to review the manufacturing operation at their alternate source location and provide advice on how to bring the tool up to 100% efficiency.
We agreed to visit their new manufacturing site to audit and review their production parameters. Our expertise quickly revealed where press and detooling processes needed improvement.
We brought tool utilization up to where our customer was able to hit not only their production volume goals but also realize their originally intended 35% part savings. The non-performance penalty was avoided, and Darcoid was asked to take on the ongoing supply of this part to maintain volumes and quality.