Production fixture for an automotive component
We designed and delivered a fixture that cut assembly time by 40% and eliminated operator errors.
Client
Tier-1 automotive supplier
Industry
Automotive
Timeline
6 weeks
Technologies
CATIA V5 · CNC milling · 3D scanning
01 — Challenge
Assembly with a high error rate
The client was facing an error rate of up to 8% in the manual assembly of sealing components. Every error meant a costly repair on the production line, a stopped cycle and re-inspection of the whole set. They were looking for a solution that would guide the operator — not just check their work.
02 — Solution
Modular locating fixture
We designed a modular fixture in AW-7075 aluminium alloy with pneumatic clamping and optical stops. The operator can only insert the component in the correct position — the wrong orientation makes clamping physically impossible. The result: zero defects from the first day in use.
03 — Approach
Process analysis
Mapping the production flow, measuring cycle times and identifying sources of error directly on the line.
Design
3D model in CATIA V5. FEA of the pneumatic cylinder load. Three design iterations before approval.
Manufacturing and assembly
CNC milled from AW-7075. Hard anodised, 20 μm. Assembly and presetting of the optical stops in the CoSTROZ workshop.
Rollout and validation
Installation on the production line, operator training and error-rate measurement during a two-week trial run.
Technical specifications
Outcome
Cycle time fell from 4:20 min to 2:35 min. The error rate dropped from 8% to 0% from the first day in use. The fixture paid for itself for the client within 11 weeks.