The result in four numbers
The full picture
A Tier 1 customer serving a European OEM needed a supplier ready to take over production of a wire harness clip at a volume of 10–12 M pcs per month. Requirements: CPK > 1.67 for the snap-fit dimension, scrap rate below 0.5%, JIT deliveries on a two-day cycle.
The previous supplier ran a 14 s cycle, which with an 8-cavity mould meant output too low for the OEM's production plans.
We designed the process around PA6 GF30 with a 16-cavity mould on an Arburg machine from our own fleet. A full Moldex3D analysis focused on fill balance (cavity balancing) and cooling channel optimisation to cut the cooling phase as far as possible.
We implemented online SPC for two critical dimensions: a sample measured every 30 minutes, with automatic escalation at a deviation > 0.6σ.
After six months of series production: 9.6 s cycle (31% shorter than the benchmark), CPK 1.71 for the snap-fit dimension, scrap rate 0.28%. OTD 100%, no quality complaints over 12 months.
The client extended the collaboration to two further size variants of the component and is considering transferring the remaining clips in its portfolio.
What was key
- A 16-cavity mould instead of 8. The investment in a mould twice the size paid for itself within 8 months of production - through a lower unit cost.
- Cavity balancing in simulation. Without the Moldex3D analysis, the 16-cavity mould would have had uneven cavity filling, causing dimensional drift - we caught it before machining.
- Online SPC. The client’s CPK > 1.67 requirement cannot be sustained without continuous monitoring - we implemented a measurement system with real-time escalation.
“It was the first time we had a supplier who proposed a 16-cavity mould. And the first time we had a supplier who kept the promise made in the first conversation.” - Senior Buyer · Tier 1 client
