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
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
Certifications & Related Case Studies
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