QC and assembly verification for the VW Caddy central console box at NIFCO

Company overview

NIFCO is a global supplier in the automotive industry, specialising in the design and manufacture of high-precision plastic components. The company is known for its commitment to quality, innovation, and meeting the stringent requirements of leading automotive manufacturers.

Executive summary

The implementation of the custom quality control device has delivered significant benefits for NIFCO, including:

• Improved assembly quality and geometric compliance for the VW Caddy central console box.
• Increased confidence in measurement results, supporting robust quality assurance processes.
• Enhanced efficiency and reliability in the assembly verification process.
• Compliance with customer requirements for precision and documentation.

Project objectives

NIFCO required a solution that would:

• Ensure quality control and correct assembly of plastic elements for the central console box in the VW Caddy.
• Verify compliance of assembled parts with the CAD design geometry.
• Achieve and maintain a measurement accuracy of 0.02 mm for the entire instrument.

The challenge

The customer needed a device capable of verifying both the correct assembly and the geometric compliance of plastic components with extremely high accuracy. Standard dial gauge solutions on the market allowed for spindle rotation, which compromised measurement precision. Achieving the required accuracy and repeatability demanded a custom approach, including robust Poka-Yoke features and reliable calibration.

The solution

A custom socket was designed and manufactured to replicate the geometry of the storage compartment environment within the passenger car dashboard. This socket enabled unambiguous manual assembly of the central console box, allowing operators to check the correct assembly of each product element. The tool was equipped with dial indicators to control geometry and verify RPS and MP points according to the customer’s drawings.

To maintain the required accuracy, a Poka-Yoke system was implemented on the dial gauge spindle, preventing unwanted rotation and ensuring consistent measurement results. Additionally, the tool included a precisely manufactured calibration socket to guarantee repeatable accuracy. The device’s performance and accuracy were confirmed by a CMM measurement report.

Key achievements

High-precision quality control

The device enables verification of assembly and geometry with an accuracy of 0.02 mm, meeting stringent automotive standards.

Reliable assembly verification

The custom socket design ensures unambiguous manual assembly and effective checking of all product elements.

Enhanced measurement repeatability

The Poka-Yoke feature on the dial gauge spindle and the dedicated calibration socket ensure consistent, repeatable measurements.

Validated performance

The accuracy of the device was confirmed by a CMM measurement report, providing confidence in the solution’s reliability.