In the competitive world of automotive manufacturing, parts and manufacturing changes can happen fast, and even minor design changes can lead to significant production challenges. This case study highlights the collaborative efforts of Shawmut Corporation to resolve a part failure caused by a material limitation in the production of automotive interior pillars. The issue arose when a leading global automotive OEM implemented a design modification, causing their Tier 1 supplier to encounter failures in their molding process.
Shawmut’s ability to quickly diagnose the root cause, apply lessons learned from previous programs, and implement a tailored solution ensured uninterrupted production and maintained the OEM’s stringent quality standards. The project underscores Shawmut’s role as a problem-solving partner, leveraging expertise in adhesive lamination to address complex manufacturing challenges.
A Tier 1 supplier encountered significant issues when the OEM altered the shape of a pillar component, creating deeper draw areas in the mold. This change caused tearing during the molding process, which relied on a material with low elongation properties. The supplier’s previous transition to a hot roll lamination process further compounded the problem, as this approach lacked the flexibility required for deep-draw applications.
The Tier 1 supplier initially hesitated to move away from the hot roll process due to historical concerns with adhesive lamination. However, as launch deadlines loomed and production failures mounted, Shawmut stepped in to address the problem. The challenge was to rapidly identify the root cause, implement a solution, and gain approvals without delaying the OEM’s production timeline.
Shawmut leveraged its expertise in adhesive lamination to provide a comprehensive solution. Drawing from lessons learned in previous collaborations with the Tier 1 supplier, Shawmut identified that the hot roll process was ill-suited for the updated mold design. The team recommended returning to a TSG adhesive lamination process, which offered the necessary elongation properties to withstand the deeper draw requirements.
Key steps in the approach included:
Shawmut’s ability to pivot and adapt existing processes was crucial to the program’s success. The TSG lamination process involved the following considerations:
Shawmut’s solution not only resolved the immediate issue but also demonstrated the value of a flexible, expertise-driven approach to material challenges. By leveraging prior knowledge and implementing a tailored solution, Shawmut enabled the Tier 1 to meet the OEM’s quality standards and maintain the production schedule.
The transition back to TSG lamination restored the necessary material properties, allowing the updated pillar design to succeed in the molding process. This solution avoided potential shutdowns, preserved the Tier 1’s reputation, and reinforced Shawmut’s role as a trusted partner in automotive manufacturing.
Shawmut’s ability to diagnose and resolve complex material issues highlights the company’s commitment to innovation and customer collaboration. This case study illustrates how tailored solutions and adaptive processes can overcome manufacturing challenges, ensuring the seamless production of high-quality automotive components. As automotive designs continue to evolve, Shawmut remains at the forefront, ready to deliver cutting-edge solutions for the industry’s most demanding applications.
Automotive Pillars: Advanced Adhesive Solutions
Shawmut Corporation
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208 Manley Street
West Bridgewater, MA 02379
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