Bossard's Crucial Role in EV Vision and Achievements

A global provider of stored energy solutions for the transportation and industrial markets. Products and services include batteries and battery systems for vehicles, standby power applications, and motive power applications. Specializes in advanced battery technology solutions, particularly lithium-ion batteries for industrial.

OPPORTUNITY R&D engagement at the design stage involves collaborating with the research and development team to specify the necessary requirements for a product. This process can help to ensure that the product meets the desired specifications and performance standards before it is manufactured.

CHALLENGE Company has limited knowledge of fastener selection for EV battery applications. This greatly benefits the customer to seek the expertise of a fastener supplier or a consultant who specializes in this area. It can help to ensure that the fasteners selected are appropriate for the specific requirements of EV batteries, which depend on factors such as the size and weight of the battery, the materials used in the battery casing, and the operating conditions of the battery.

ACTION TAKEN Despite COVID restrictions, the proposed virtual teardown helps the company's eagerness to find more innovative solutions. The company may need to leverage remote collaboration tools and technology to enable virtual teardowns and continue its efforts to identify solutions. This may involve utilizing video conferencing, remote access to testing equipment, and other virtual collaboration tools.

RESULTS Proposed solution is to standardize fasteners, material, and plating. Their commendation is to use base materials that match the mating materials to avoid corrosion and ensure a longer service life for the fasteners, with the use of stainless steel for corrosion protection where needed. Standardization reduces storage, streamlines inventory, and lowers costs. The company has saved 945 hours of time.

The company specializes in the production of electric scooters and bikes, with a focus on providing affordable, high-quality EVs for the Indian market. Its products are designed and developed in-house, and it has a manufacturing facility in Goa, India.

OPPORTUNITY The customer has requested our support in selecting fasteners for the model based on the actual application, material, and issues in assembly. Bossard worked with the customer to identify the most appropriate fasteners that are suitable for the specific requirements in the application, taking into consideration the materials involved and any issues that may be raised during assembly.

CHALLENGE The customer is facing pain points and challenges with their initial lot of the model, as they have received market feedback indicating quality issues such as rusting, boss rupturing, cracks in the plastic, and loosening due to vibration. The following are some of the customer's challenges. 
- Quality issues (rusting)
- Boss rupturing and crack in the plastic
- Loosening due to vibration

ACTION TAKEN Our company provides a detailed joint study and total cost of ownership (TCO)analysis through an expert teardown process. In this process, we disassembled the customer's product into its single parts and fasteners and analyzed the interface complexity of each component. Our technical specialists examine every inch of the product to understand its functionality and identify potential cost savings, as well as opportunities to improve the quality and reliability of the model

RESULTS We analyzed the model and suggested reducing plating types to two, eliminating rejection of mating parts, preventing vibration loosening, and introducing a special collar to the steering column assembly. These improvements reduce risk and save 158 assembly hours.

The company is a comprehensive manufacturer specializing in developing and producing various types of internal combustion engine-powered equipment and vehicles. They offer generating sets, agricultural machinery, light-duty power units, and motorcycles. The company also ventures into emerging businesses that leverage its internal combustion engine technology expertise.

OPPORTUNITY The company has established stable strategic partnerships with globally renowned enterprises. They operate as a world-class power system manufacturer with a presence in over 100 countries and regions worldwide. Since 2017, their customer engineering team has engaged Bossard for their Expert test services and Expert design. The company uses many specialized engineering components and screws to produce their various engines.

CHALLENGE Motorcycle engine automated assembly lines have a high requirement for the stability of the friction coefficient of the fastener. In joint venture projects, the R&D is responsible for the evaluation and localization of parts. Customer engineers lack fasteners application experience and need a reliable supplier to provide Engineering support and reliable quality parts

ACTION TAKEN 
- Demonstrated our value-added services through technical seminars and actions, training customers on improving design efficiency, reducing risks, and providing daily engineering support to address product failures and improve design and process flow.
- Our Coefficient of Friction tests showcases our engineering values, which are highly appreciated by our customers.

RESULTS Our engineering services have proven to enhance customer loyalty and secure additional projects for us. Currently, we are supplying our solutions to one project, while another project is already underway. Through our technical support and product solutions, we have successfully improved the stability, safety, and production efficiency of our customers' products, leading to significant qualitative benefits. Moreover, our expertise in assembly technology includes conducting friction coefficient tests, allowing us to optimize fastener design and achieve substantial cost reductions.