Pressings takeover work
Drivetrain & Engine Presswork Recovery Project
Restored predictable supply in 4 weeks across 32 drivetrain tools while slashing defects by 73 %.
Quick Facts
- Customer: Tier 1 automotive OEM
- Sector: Passenger-vehicle drivetrain & engine
- Component: 32 stainless-steel drivetrain / engine parts
- Volume: 360,000
- Lead‑time: 4 weeks (tool hand-over → Initial PPAP)
Customer Profile
A Tier-1 automotive supplier shipping millions of power-train assemblies yearly. When their incumbent presswork supplier faltered, they needed a partner that could absorb 32 existing tools, restore quality and hit tight engine-plant delivery windows—fast.
The Challenge
Late deliveries were cascading through the customer’s line because quality spillages at the previous stamper drove scrap to 300 PPM. Poor process control meant emergency air-freight and costly line-stops were becoming routine.Engineering Solution
Rapid turnaround: accepted all 32 tools and produced conforming parts inside 4 weeks.
Full strip-down & inspection: each die laser-measured, worn sections refaced or replaced.
Planned upkeep: a preventive-maintenance plan integrated with our ERP to schedule die-service automatically.
Matched presses: tools reassigned to optimal lines—Fagor 250 T, Chin Fong 400 T, Bruderer 60 T progression—to stabilise forming forces.
Inline checks: added in-process dimensional probes; Cpk tracked live to our quality dashboard.
Innovation & Value‑Add
Digital maintenance logs trigger tool refurb before wear hits tolerance drift—keeping OEE above 90 % without affecting customer schedules.
Results & KPIs
| Metric | Before takeover | After stabilisation | Improvement |
|---|---|---|---|
| Scrap / reject rate | 300 pPM | 80 pPM | –73 % |
| On-time delivery | 41 % | 100 % | +59 pP |
| Lead-time to PPAP | — | 4 weeks | n/a |
Customer Quote
“Brigham hit our aggressive timeline while cutting cost per part.”
Visual Proof
Tech Specs
Materials: Stainless Steel 304
Thickness range: 0.9 mm / 1.2 mm / 2 mm
Presses: Fagor 250 T, Chin Fong 400 T, Bruderer 60 T (progression)
Post-processing: Degreasing operation
Tolerances: ±0.05 mm on critical datums
Certifications & Related Case Studies
IATF 16949 | PPAP Level 3
See Product Improvement case →
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