Assembly experts revolutionize electrical and electronic equipment industries

Located in Nanjing, China, our customer is a company that excels in the integration of research and development, manufacturing, and sales of power tools and smart outdoor garden equipment. Their dedication and expertise have earned them numerous honors and recognitions, including the titles of a national green factory and a national industrial design center.

Opportunity
To boost the capability of a well-known power tool, our engineering team engaged with our customer R&D department in Expert Assortment Analysis and Expert Teardown projects. Throughout this collaborative process, thread-forming screws and self-tapping screws have been extensively utilized on the product shell.

Challenges
In their day-to-day production processes of power tools at their Nanjing plant, our customer faces several challenges. Our engineers have identified the following key challenges:
1. Multiple types of products to manage
2. Complex assembly process in production
3. Fasteners have a risk of failure in the whole machine rework, such as cam-out

Actions taken
Through daily visits and engineering interactions, we were able to hold a technical seminar to train their engineers focusing on improving design efficiency and reducing risks by utilizing thread-forming screws. We provided technical clarification on the superior performance of ecosyn®-plast compared to self-tapping screws, which effectively resolved product failures.

Customer benefits
Our engineering services have significantly increased customer satisfaction and opened doors to special opportunities. The use of special self-tapping screws, specifically designed for plastic parts like ecosyn®-plast, is resulting in a notable 20% reduction in rework. Additionally, due to Bossard's advanced solutions, the customer has achieved an impressive 25% decrease in the total cost of the assembly process each year.

The customer, a prominent electrical and electronic equipment manufacturer in China, specializes in producing a wide range of products, including high-voltage devices, low-voltage devices, transformers, switchboards, PLCs, inverters, and automation devices.

Opportunity
The customer seeks to enhance production efficiency and optimize fastening applications with the assistance of Bossard's Expert Teardown service

Challenges
Some of the customer's challenges in their low productivity assembly process, including:
1. Inefficient nameplate attachment.
2. Low efficiency caused by the use of anti-galling grease applied to stainless steel fasteners.
3. Reduced efficiency due to the application of thread anti-loosening glue on the screws.

Actions taken 
To address these challenges, the following actions were taken: Consideration of using speed rivets instead of semi-screws for faster installation, replacement of Loctite-LB 8150 with Everlube 620C as a pre-lubricant alternative and the utilization of pre-coated patches as a convenient and reliable sealing alternative to Loctite-243.

Customer benefits
Through engineering services, increasing customer stickiness by helping the customer to overcome the stainless steel fastener galling issues can be achieved. Additionally, the thread-locking glue is applied more evenly, resulting in a good anti-loosening effect. Production efficiency improvement 30% with Decease 4% cost and reduce costs by 51%,translates to 4,945 working hours annual. Savings equivalent to 2.4 headcounts.

The customer is a global leader in providing safety identification and compliance solutions. Their product portfolio includes portable, desktop, and industrial printers, along with versatile barcode scanners for effective tracking applications. In Malaysia, their primary focus lies in providing exceptional support for key products, specifically labels and printers.

Opportunity
To maximize customer success and minimize product life cycle costs, it is crucial to prioritize the selection of optimal fastening solutions. By carefully considering factors such as cost and safety, we can effectively showcase the value of Assembly Technology Expert services to customers.

Challenge
To ensure economical part costs, it is evident that the use of imperial size screws may not be the most cost-effective approach. In light of this, we propose a transition from imperial to metric size screws for future support. This transition will enable every site to seamlessly make the switch, minimizing any risks associated with secure joint integrity during the partial change.

Actions taken

• Switch from imperial to metric size screws for future support across all sites to improve cost-effectiveness.
• Recommend the use of ecosyn®-fix as a replacement for conventional screws with washers.
• Propose fan mount rivets as an alternative to conventional screws and nuts.

Customer benefits
Optimizing the fastening system involved replacing 30 imperial size screws with 22 metric size screws results in a significant 21% annual process time savings, enhancing overall efficiency.

The Korean customer is an electrical manufacturer that produces high-voltage devices, low-voltage devices, transformers, switchboards, PLCs, inverters, and automation devices. With the highest market share in the Korean circuit breaker industry, this manufacturer has established a remarkable sales record, reflecting their strong presence and success in the market.

Opportunity
By collaborating with our R&D team, the customer was presented with a range of our engineering services, designed to enhance productivity and achieve cost savings. As a result of this engagement and an Expert Teardown, the customer was able to identify areas in their current circuit breaker model that could benefit from improvement.

Challenge
Bossard proposed three solutions based on a TCO report. These solutions encompass eliminating the Loctite application line, optimizing machining parts, and providing guidance on the optimal boss design for the integration of the new spiral cutting screw into vibration testing. With the implementation of Bossard's Expert Design, customers gain the opportunity to significantly enhance the quality of their end products in a lasting manner. This comprehensive service offers valuable recommendations on materials, assembly conditions, and prototyping, empowering customers to achieve improved product outcomes.

Actions taken
Through frequent visits and engineering interactions, we gained customer trust and conducted a technical seminar to train their engineers. To enhance design efficiency and minimize risks, we implemented thread-forming screws and clarified the superior performance of ecosyn®-plast compared to self-tapping screws, resolving product failures effectively.

Customer benefits
By eliminating the requirement for Loctite auto-apply and mitigating issues related to loosening, the customer can enjoy a substantial 35% reduction in Total Cost of Ownership (TCO).