Fortune 100 Domestic Supplier – Starter
The components of this housing assembly were already sourced by Asia America. During an onsite customer visit, Asia America noticed the customer had hundreds of rejected starter motors and learned that for years, the customer had a 40% failure rate on final testing due to air leaks around a piston and O-ring assembly.
Asia America built a press tool for the piston/O-ring process and offered to subassemble the components, pressure test, kit and then send to customer.
The results were amazing – zero defects. The savings to the customer were significant:
Production line efficiency improved by over 40% due to the reduced labor needed to build a finished starter.
The production cell was consolidated into a smaller area. (The customer no longer needed a tear-down area for rejects.)
The net cost of a starter was reduced by the amount of all the scrapped parts they would have to pay for due to their less efficient assembly. For remanufactured starters, this helped the customer reduce the amount of seeding in a starter. The reduction resulted in savings of $110,000 a month on seeding.
Asia America now provides 2- and 3-piece kits to the production line and this component has become one of the most profitable lines for the customer.