Electrical · export program
A three-piece cable gland consolidated into a single moulding — assembly cell deleted, unit cost down 31%.
A cable gland arriving as body, nut and seal — three tools, three inspections, an assembly cell and a scrap rate nobody wanted to talk about.
A DFM pass merged the sealing petals into the body and moved the thread into the cavity. One tool, one shot, one part number.
Assembly cell removed. Cost per unit fell with it, and the part now ships to two EU distributors on a rolling forecast.
Body, nut, elastomer seal. Each with its own tool, its own lead time, its own inspection gate. Every unit passed through hands before it passed through a box.
We modelled the sealing petals as living features of the body wall and cut the thread directly into the cavity with an unscrewing core. The elastomer seal became geometry instead of a component.
The part now runs on the 120 t Chen Hsong in a four-cavity tool. Scrap is measured per shift and logged against the mould, not the shipment.
Every line was measured on the same programme, before and after the change.
| Before | After | Δ | |
|---|---|---|---|
| Parts per assembly | 3 | 1 | −2 |
| Tools maintained | 3 | 1 | −67% |
| Unit cost (index) | 100 | 69 | −31% |
| Assembly labour | 1 cell | None | −100% |
| Scrap rate | 4.1% | 0.8% | −80% |
| Lead time | 42 days | 21 days | −50% |
“The line stopped being an assembly line. It became a packing line.”
Send a drawing or a sample. You get a DFM read, a tool plan and a cycle estimate — not a brochure.
