Taking Over a Failing Stamping Program — and Guaranteeing Zero Missed Components
When a supplier's quality and delivery problems put an OEM production line at risk, the tooling came to AMG. First finished-product shipment was needed within one week. Here's how we did it — with a completely manual operation and no automation or investment required from the customer.
1 week
From tooling arrival to first finished-product shipment
18,000
Finished assemblies delivered per week
$15,000
Potential OEM back charge per missed-component incident
$0
Automation or capital investment required from the customer
The Challenge
The customer was experiencing significant issues with both quality and delivery from their existing supplier. The most dangerous failure mode: one out of four components — a fastener — was not being installed during the stamping operation.
A single missed fastener carried a high potential of off-lining a vehicle at the OEM location, with a back charge of up to $15,000 per incident — essentially stopping the production line at the OEM.
AMG Industries was challenged with implementing a process that would guarantee no missed componentry — with no automation or investment by the customer, a completely manual operation, and delivery of up to 18,000 finished assemblies per week.
The Solution: Layered Error-Proofing in Three Months
Tooling was delivered to AMG with the first finished-product shipment needed within one week. We shipped on time, then systematically error-proofed the process. Within a three-month period, we had completed the following:
200% Visual Inspection — Immediately
From the first production run, every assembly was visually inspected twice, protecting the customer while a permanent error-proof / mistake-proof system was engineered for the stamping process.
Proximity Sensors on Every Component
Proximity sensors were added to verify that each assembled product contained all four required components — catching a missed fastener before it could leave the operation.
In-House Camera & Gauging System
AMG designed and built a camera system internally that blocks mis-aligned fasteners from being processed further, prevents right-hand and left-hand parts from being mixed, and positively identifies every part as having been 100% gauged.
Locked-Down Release
If any of those criteria go unmet, the part will not be released from the gauge. Only supervisor or maintenance personnel can release it — a nonconforming part physically cannot continue down the line.
Why Takeover Work Moves Fast at AMG
With takeover work, we have demonstrated turnaround times of less than two weeks. Because the tooling already exists, the long lead-time item of a typical program launch is off the table — new program timing is normally driven by tooling lead times, with stamping carrying the longest and assembly and fabrication the shortest.
AMG provides stampings, assemblies, and fabricated and machined products for the automotive, heavy truck, agricultural, and solar industries, among others.
- • Stamping: small to medium components requiring 50–300 tons, material gauge up to 0.250" in carbon, aluminum, and stainless steel.
- • Fabrication: up to 120" in length and 0.250" thickness in carbon, aluminum, and stainless steel.
- • Machining: evaluated case by case — from a single milling or turning operation to a fully automated, multiple-operation process.
Weighing a supplier switch? Run the full cost math first
Chargebacks, expedites, and quality escapes rarely show up in a piece-price comparison. Our free TCO analysis covers the 12 cost factors that decide what a part really costs — with a worked example on a real automotive part.
Built for the CFO conversation
Have a Program in Trouble?
If a supplier is putting your quality, delivery, or production line at risk, AMG can take over existing tooling and ship fast. Tell us about the program and we'll respond with next steps.
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