Towards a High-Performance Product for the Future EV 2 Wheeler

The company specializes in the production of electric scooters and bikes, with a focus on providing affordable, high-quality EVs for the Indian market. Its products are designed and developed in-house, and it has a manufacturing facility in Goa, India. 

OPPORTUNITY 

The customer has requested our support in selecting fasteners for the model based on the actual application, material, and issues in assembly. Bossard worked with the customer to identify the most appropriate fasteners that are suitable for the specific requirements in the application, taking into consideration the materials involved and any issues that may be raised during assembly. 

CHALLENGE 

The customer is facing pain points and challenges with their initial lot of the model, as they have received market feedback indicating quality issues such as rusting, boss rupturing, cracks in the plastic, and loosening due to vibration. The following are some of the customer's challenges. - Quality issues (rusting) - Boss rupturing and crack in the plastic - Loosening due to vibration 

ACTION TAKEN 

Our company provides a detailed joint study and total cost of ownership (TCO)analysis through an expert teardown process. In this process, we disassembled the customer's product into its single parts and fasteners and analyzed the interface complexity of each component. Our technical specialists examine every inch of the product to understand its functionality and identify potential cost savings, as well as opportunities to improve the quality and reliability of the model 

RESULTS 

We analyzed the model and suggested reducing plating types to two, eliminating rejection of mating parts, preventing vibration loosening, and introducing a special collar to the steering column assembly. These improvements reduce risk and save 158 assembly hours.