case study #1
continental
PROBLEM: Continental Automotive’s Newport News plant was managing a low-volume, highly complex diesel injector. When Continental received $100 million of new capital to support a new product launch, they knew they needed a solution to remove the old diesel injector from their lineup so they could concentrate on their new programs.
SOLUTION: We crafted a contract that would allow PurePower to buy all existing capital, take over the supply base for costed bill of materials and PPAP the product within our facility in Blythewood. Our program managers oversaw the whole process, complete with a production buildup of three months to accommodate the time for transfer and to requalify the equipment.
RESULT: Flawless execution. We completed the buildup with zero quality defects, completed transfer and requalification of equipment faster than estimated, and completed PPAP on time with the customer — all with zero defects from launch to present.
case study #2
navistar
PROBLEM: Navistar had an overseas supplier that was shipping poor-quality components that were causing engine line downtime. The supplier was not capable of machining for very close tolerance dimensions — under 10 microns — with complex GD&T reference to multiple datums.
SOLUTION: Within eight weeks, we created a fixture, programmed a Mazak 630 VMC, qualified the fixture, completed level 3 PPAP, and shipped the product in custom returnable dunnage. The part has been defect-free for over three years.
RESULT: Our customer’s issue was resolved with zero line downtime for this component.
case study #3
Fuel System Tech Startup
PROBLEM: Many startup companies have invested heavily in advanced development capabilities and IP. What most of them lack is the infrastructure to design a product that can be manufactured, make prototypes, and test these prototypes.
In this particular case, the company had OEMs willing to test its product if it was able to show that:
- El producto podrÃa fabricarse en grandes cantidades a un coste razonable, y
- Los resultados de las pruebas de rendimiento del producto mostraron mejoras en comparación con las tecnologÃas predominantes
SOLUTION: Dado que PurePower lleva más de 15 años diseñando y probando componentes de sistemas de combustible en un entorno de gran volumen, pudimos proporcionar una amplia ayuda, rediseñando el producto junto con el cliente. Proporcionamos un diseño y un presupuesto de producción para demostrar la viabilidad del producto para la producción de grandes volúmenes. Se realizaron pruebas en nuestros bancos de pruebas de rendimiento, que demostraron que el producto era superior a la tecnologÃa actual.
RESULT: El cliente pudo entonces completar el siguiente paso, que consistÃa en someter su producto a pruebas en distintos fabricantes de equipos originales.
