CUSTOMER CASE STUDY

May 2018

Discover our latest case study on how to successfully implement production for complex electromechanical assemblies

ABOUT THEM

The Customer.

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Mainly Box Build, Mechanical and PCBA. Product used to test cars‘ battery by simulating different running conditions. Trusted and long-term customer of Asteelflash.

Multinational Automotive Company. This product was build internally in a Lab for years at prototyping stage.

Customer wanted to send it to mass production.

“We have been working with this customer for years. This is a long-term relationship based on trust. It is always exciting to start working on a new project with them”

– Albert Yanez Sr., EVP and President of the America’s

Global leader within Electronic Manufacturing Services (#2 European EMS).

Over 20 years of experience with seasoned, talented employees.

State-of the-art manufacturing capabilities in every region.

From PCBA to full turnkey solution.

Founded in 1999

ABOUT US

About Asteelflash.

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FOR ASTEELFLASH

Challenges. Unusual Form Factor of the product: Height : 150 cm | 59 inch - Large: 120 cm | 47.2 inch - Length: 100 cm | 39.4 inch Mainly mechanical project, with few PCBAs. Sheet metals assemblies, harness assemblies, cooling system.

Challenge in mechanical assembling that required to handle heavy parts, such as transformers for e.g.

High Voltage testing required: high level of safety equipment to be implemented, meet specific requirements, additional trainings for staff necessary, plus a permit from the city was mandatory.

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FOR ASTEELFLASH

Challenges.

Training of Operators to follow specific instructions from the customer and this specific type of test. Create production lines and dedicated work space from scratch, plus need to purchase additional Mechanical tooling. Most of the customer’s suppliers in AVL/BOM were not in our system. We needed to qualify, approve and add them to our internal system for our buyers to be able to procure the materials. Most Suppliers on the AVL were slow in responding with their requirements, qualifications and quotations.

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First time that the customer was externalizing this product for mass production.

Deadlines were extremely short. Project was won in mid-July and staring date in September.

BoM and drawings weren’t accurate enough and not adapted for mass production.

Hard to go from laboratory to production line due to difference of organization between the Customer and Asteelflash.

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FOR THE CUSTOMER

Challenges.

Conceptual design study with regard to costs, deadlines and flexibility. Material and supplier selection through our procurement teams. Development of different types of tests. Set up of High Voltage functional testing. Pressure testing. Dedication of a room for High Voltage testing. Good job from teams : operators, engineers, technicians and all co-workers involved. Development and design of fixtures, forklifts, and visual aids to have smooth and more efficient production. Good relationship & communication with the customer : great support from both sides.

ASTEELFLASH

Our Solutions.

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ASTEELFLASH

Our Solutions.

Purchasing and manufacturing of customized tooling to ensure efficiency of the product and to meet his specifications (such as size, weight, mechanical constraints…). Improvements of the Manufacturing process to meet the customer expectations. Successful New Product Introduction (NPI) and go-to production. Design for Manufacturing : Solutions proposed to build the unit in a production environment.

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RESULTS & ACHIEVEMENTS

Very positive feedback from the customer : Complete satisfaction! The project went through efficiently and without problems. No objections during or after the project : true teamwork project. Good collaboration between Asteelflash & customer’s engineers.

8/8

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