Chemical-Compound Applicator Redesign for Assembly Lines
Six-week tooling turnaround delivery, cut change-over time while improving operator ergonomics.
Quick Facts
- Customer: Global dispensing-systems OEM
- Sector: Automotive & Aerospace assembly lines
- Component: Chemical-compound applicator trigger & plate
- Volume: 900,000
- Lead‑time: 8 weeks
Customer Profile
A leading global supplier of hand-held dispensing systems used on automotive and aerospace assembly lines. The customer needed to launch a lighter, easier-to-service chemical-compound applicator but had limited in-house expertise with high-volume press tooling. They turned to us for rapid design-for-manufacture guidance and tool sourcing to keep their production ramp on schedule.
The Challenge
Operators found the legacy assembly was heavy and awkward, extending change-overs and disrupting takt time on high-speed automotive and aerospace lines. The customer needed a redesigned set of parts—fully press-formed in DC04 mild steel—capable of 900,000 units per year and with ergonomics and change-over performance that met their new operational targets, all within a six-week tooling window.
Engineering Solution
Collaborative DFM workshops turned the customer’s CAD into two press-ready parts: a 2.3 mm DC04 and a 1.6 mm DC04. 3-D ergonomic modelling refined finger contours while keeping the mounting envelope identical, so the new assembly dropped straight into existing tools on the line.
Six-week tool build: followed by one week on-site commissioning, brought both dies to full production speed with zero schedule slip.
Press-line allocation: Chin Fong 250T, Bruderer 60T, S&B 50T.
Ergonomic gains validated: during on-site trials operators confirmed the new assembly met the required hand-force window and achieved the customer’s target change-over time—eliminating the downtime complaints that triggered the project.
Innovation & Value‑Add
New tooling was developed with wear-resistant dies and easy-maintenance features, and the customer was pleased with the outcome.
Results & KPIs
| Metric | Outcome |
|---|---|
| Tooling delivery | Built in 6 weeks, commissioned in 1 week—on schedule |
| Change-over performance | Met the customer’s target time; operators reported smoother swaps |
| Production readiness | Tooling qualified for 900,000 units per year |
Customer Quote
“The new tooling went in flawlessly and delivery performance has been excellent.”
Visual Proof
Certifications & Related Case Studies
Tech Specs
Materials: Mild Steel DC04
Thickness range: 2.3mm, & 1.6mm
Presses: Chin Fong 400 T, Bruderer 60T, S&B 50T
Tolerances: ±0.05 mm on critical datums