problem
Car window frames frequently became dislodged, resulting in an unacceptable complaint ratio of 24% and immense warranty costs.
In addition to these quality issues, the required parts were very expensive, and the customer did not receive value for money.
Thorough analysis showed that the cause was a design flaw in both the original manufacturer parts and the aftermarket parts.
Missing fitting instructions resulted in an inefficient and time-consuming installation process.
SOLUTION
It soon became clear that 1-on-1 replacement of parts (reverse engineering) would not suffice, despite the price advantage this offered. AIP then initiated a redesign process for the critical components of the car window frames. Starting with a 3D design and moving on to a prototype, we tried to find the optimum alternatives. After extensively testing the functional advantages of the milled samples, we began serial production.
result?
A happy customer, and not just because of the reduction in the cost of replacement parts. The redesign also resulted in a more efficient installation process.
✓ 50% time saved during the fitting process
✓ 100% fewer complaints with regard to the assembly issue
✓ A more competitive market position
✓ Significant increase in end customer satisfaction