CASE STUDY
HALL32, located in Clermont-Ferrand, France, is a renowned industrial innovation and training hub dedicated to fostering advanced manufacturing solutions. With a strong focus on collaboration, technology development, and workforce training, HALL32 bridges the gap between industry needs and innovative engineering practices.
Location: Clermont-Ferrand, France
Segment: Railways
Background: HALL32 approached Punch Powertrain Engineering Services (PPES) to address a production run of 880 acoustic transducer units. The project scope included applying Design-to-Cost and Design-for-Assembly methodologies to optimize the product design and assembly process, along with the development and management of the supply chain for primary components.
Solution:
To address these challenges, PPES applied the Design-to-Cost and Design-for-Assembly methodologies to optimize both the product design and the manufacturing process. This allowed us to achieve initial productivity from the first production batch, despite the constraints imposed by the tight schedule.
Key actions included:
- Defining a roadmap for ongoing improvements to forecast future needs and associated productivity enhancements.
- Addressing supply chain challenges by leveraging our existing supplier panel while consulting new suppliers for components outside the automotive sector. Our purchasing and logistics teams supported the effort to achieve the best QCD outcomes.
- Applying standardized product/process bricks developed in previous projects. This streamlined the setup of the manufacturing process, enabling us to meet delivery deadlines efficiently.
Throughout the project, everyone adapted and gave their best to achieve the goal, overcoming obstacles and racing against time. Together, we accomplished an extraordinary achievement.
Results:
Despite the difficulties encountered by HALL32 that were outside our scope, PPES not only achieved the initially set objective but also helped HALL32 recover the delays caused by these obstacles. The result? For an initially defined production target of 880 parts to be completed in 4 months, PPES successfully produced 982 parts within the same timeframe, despite stoppages beyond our control.
This project showcased PPES expertise in industrialization, product development, and implementation (PD&I). It highlighted our professionalism, agility, and responsiveness, as well as our ability to balance rigor and technical knowledge to achieve cost-efficient production.
The success of this project led to a new long-term partnership with HALL32. A new production plan is already in place for 2025.
Key Numbers
Delivery of 100% tested, high quality products to the end customer on time
Customer Satisfaction Rating
Parts Produced
(Target:880)