The challenge
A leading manufacturer of solenoid valves for use in HGV transmissions had to localize its supply chain in China. This was necessitated by the requirements of its customers as well as a massive increase in demand for the valves in China.
One of the critical components in the solenoid valve was causing the producer a lot of headaches. Not only were there special requirements relating to the soft magnetic stainless steel, but also very high requirements for the coating of the components. Inadequate coating would inevitably lead to premature valve failure and damage to the transmission.
The special nature of the task
The component is a relatively simple, conventional CNC straight-turned part made of soft magnetic stainless steel. The challenges lay in both the handling and coating. The soft magnetic materials are more susceptible to damage during handling due to their lower hardness after tempering during the manufacturing process. On top of that, the selected material is also susceptible to rust.
The Dakoko solution
Dakoko provided the customer with comprehensive support in successfully localizing manufacture of the components. This began with identifying an efficient steel supplier who could offer significantly better terms than the previous European steel supplier. A suitable coater was also identified. Dakoko’s Project and Quality Department supported the company in improving critical process management areas in order to consistently meet the critical requirements of this project.
Details that make the difference
For handling, Dakoko set up special trays and washing baskets in production to prevent damage. Processes were also established to prevent rusting of components through faster handling in air-conditioned rooms. The subsequent storage of the products in a special packaging solution ensures trouble-free storage for 12 months without the need for any rust protection on the components. Dakoko developed the packaging solution in cooperation with a leading German VCI packaging manufacturer. During process development, countless tests were carried out in climate chambers to ensure the reliability of the packaging solution.
Benefits for the customer
- Localization of the supply chain in China for the Chinese plant
- Cost reductions through savings in raw materials
- Reliably meeting the high quality requirements in the coating area through supplier development by Dakoko