Quality Problem With Other Supplier Solved

This safety critical component is the emergency shut off for an automobile gas tank. If a passenger car is involved in a rollover accident, this component seals the gas tank to assure fuel does not leak out and add fuel to a fire.
This part had been run at two previous injection molders but both of them struggled to produce consistent parts that met the customers' quality requirements.
By the time the part had been awarded to our molding facility. The customer had mandated that this 8 cavity mold needed to be packaged in separate boxes & labeled by cavity number. This gave the customer the ability to sort by cavity # if required and keep their production lines running.
We took this mold over and designed an automated injection system where the parts were taken out of the mold automatically separated by cavity number and then dropped into cooling lanes to make sure the parts cooled consistently and were ready to be packed.
Our automation and cooling process solved the inconsistencies the other suppliers we're seeing.
We have been awarded 3 additional versions of this part and the customer no longer has production problems with these types of parts.
Once we solved this problem. The customer was able to significantly reduce the inventory they were holding because they no longer have quality concerns and we deliver the parts via Kan Ban to keep their inventory low.

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