Implementing a new product on an existing line at Nexteer

Company overview

Nexteer is an international company in the automotive industry, specialising in the manufacture of advanced steering gear systems for passenger cars. With a strong focus on innovation, quality, and efficiency, Nexteer serves leading automotive manufacturers worldwide.

Executive summary

The implementation of these improvements has delivered substantial benefits for Nexteer, including:

• A significant increase in production capacity, with the ability to produce 1.2 million units annually.
• Greater assembly process security, supported by advanced controls and traceability.
• Enhanced product quality, thanks to the improved accuracy of critical machinery.

Project objectives

To support the launch of a new product and meet increasing market demands, Nexteer initiated a project with the following main objectives:

• Increase production efficiency to 1.2 million units annually.
• Secure the assembly process, including insertion force, torque force, and assembly correctness.
• Improve the accuracy of the machine responsible for eliminating steering gear backlash.

The challenge

Introducing a new product on an existing production line presented several challenges. Nexteer needed to significantly increase output while maintaining strict quality standards. Ensuring the precision of assembly processes and enhancing the accuracy of critical machinery were essential to achieving these goals.

The solution

Nexteer undertook a comprehensive modernisation of its production line, focusing on both equipment upgrades and process improvements. The project included:

• Modernising 14 machines to support the new product and higher production volumes.
• Implementing additional process controls to monitor key assembly parameters, such as insertion force and torque force.
• Introducing new traceability systems to ensure complete process transparency and product history.
• Upgrading the backlash-eliminating machine to achieve greater accuracy.

Key achievements

Increased production efficiency

The modernized line now supports an annual output of 1.2 million units, enabling Nexteer to meet growing customer demand.

Enhanced process security and traceability

Additional process controls and new traceability systems have been implemented, ensuring assembly correctness and providing comprehensive data for quality assurance.

Improved machine accuracy

The accuracy of the backlash-eliminating machine has been increased from 0.3 mm to 0.03 mm, significantly enhancing product quality and performance.