Customer Challenge

Our customer was sourcing a key suspension part internationally but faced significant issues with field failures and quality. The parts were cracking, leading to operational disruptions, increased costs, and potential safety concerns for end-users. The customer needed a reliable metal stamping solution to maintain their reputation and ensure the safety and performance of their products.

Metal Stamping and Welding Solution Provided

The HTT’s engineering team took a proactive approach by collaborating closely with the customer’s engineering team. They conducted a comprehensive evaluation of the parts, including material analysis, stress testing, and failure mode analysis. The team identified that the cracking was due to stress concentrations in the metal stamping design.

To address this, HTT’s engineering team implemented a process change that allowed the part to form with a controlled gap in the design. This gap was then MIG welded to ensure the part met its intended use without failures. The solution also included rigorous testing and validation to ensure the new design would withstand real-world conditions.

Result

The metal stamping process changes and subsequent welding eliminated the cracking issue, resulting in parts that performed reliably in the field. This not only resolved the quality issues but also restored the customers’ confidence in their supply chain. The customer experienced:

  • Enhanced Product Reliability: The parts no longer cracked, ensuring consistent performance and safety.
  • Operational Efficiency: Reduced downtime and operational disruptions due to part failures.
  • Cost Savings: Lowered costs associated with returns, replacements, and warranty claims.
  • Improved Customer Satisfaction: The end-users experienced fewer issues, leading to higher satisfaction and loyalty.

Lessons Learned

  • Design for Manufacturability: Engaging with customers early in the design process can prevent issues and optimize part performance.
  • Collaboration: Close collaboration between engineering teams is crucial for identifying and solving complex metal stamping problems.
  • Process Innovation: Adapting and innovating manufacturing processes can lead to significant improvements in product quality and reliability.
  • Comprehensive Testing: Rigorous testing and validation are essential to ensure new designs meet real-world demands.

This case highlights the importance of end-to-end customer solutions and the value of working closely with customers to address and solve their unique metal stamping challenges. By leveraging our engineering expertise and innovative processes, HTT was able to deliver a solution that not only met but exceeded the customer’s expectations, ensuring long-term success and satisfaction.

HTT specializes in high volume end-to-end supply of services for metal stamped components and assemblies.  We simplify the supply chain and utilize upfront design consultation to streamline manufacturing requirements. Our approach ensures high quality, on-time delivery, and optimizes costs. As a result, our customers can save time, realize best-value pricing, and gain a reliable partner.