This part was originally made by joint welding two components, but
the welding stability was not high and 8% defect rate was reported. Due to
repeated customer complaints, we improved the process based on customer¡¦s
application need.
According to the application, we adopted clinching process and
preserved a space for punching hole in the plate. We redesigned the stud from
cutting process to cold forging and preserved tolerances for pressing.
Through prototype testing, we found both the tensile strength and
application function meet customer¡¦s requirements. So we phased into mass
production. By this re-engineering, we saved 42% for our customer and reduced
the defect rate to 0.25%. Our customer is very happy with the new design.
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