Implementing a new product on an existing line at BWI Group

Company overview

BWI Group is an international company in the automotive industry, specialising in the manufacture of shock absorbers for passenger cars. With a reputation for quality and innovation, BWI supplies advanced suspension solutions to leading automotive manufacturers worldwide.

Executive summary

The project has delivered significant benefits for BWI, including:

• The ability to produce both the new and existing product variants on the same line.
• Improved process reliability and product quality, supported by advanced automation and precise calibration.
• Minimal disruption to ongoing production, thanks to careful scheduling of modernisation activities.

Project objectives

To support the launch of a new product variant for the VW Tiguan, BWI initiated a project with the following main objectives:

• Launch a new variant for the VW Tiguan, while maintaining the capability to produce the current product.
• Modernise 24 stations on the rotary table.
• Ensure pressing accuracy within 0.005 mm.

The challenge

Introducing a new product variant on an existing production line required significant upgrades, all while maintaining ongoing production of the current variant. Achieving the required pressing accuracy and process capability demanded precise engineering and careful planning, particularly given the need to minimise production downtime.

The solution

BWI undertook a comprehensive modernisation of its rotary table, focusing on both equipment upgrades and process calibration. The project included:

• Complete modernisation of the machine, carried out during planned shutdowns and weekends to avoid disrupting regular production.
• Implementation of new stations, including grippers designed for 0.5 mm shims and vibratory feeders to ensure reliable component supply.
• Calibration of the process to meet the required Cpk, ensuring consistent quality and process capability.

Key achievements

Seamless product launch

The new variant for the VW Tiguan was successfully launched, with the line retaining full capability to produce the existing product.

Comprehensive modernisation

All 24 stations on the rotary table were modernised, with upgrades completed during shutdowns and weekends to minimise impact on production.

Enhanced process accuracy and capability

New stations, including precision grippers and vibratory feeders, were implemented, and the process was calibrated to achieve pressing accuracy within 0.005 mm and meet the required Cpk.