CASE STUDY | AUTOMOTIVE
LOWER COSTS. CONSISTENT QUALITY. ON-TIME PRODUCTION
When a Fortune 500 automotive manufacturer launched a new line of anti-lock brake sensors, it needed a reliable manufacturing solution that could deliver consistent brazed assemblies while controlling production costs and meeting demanding delivery schedules.
Rogers Metal Services developed a brazing solution that helped move the new product into efficient, repeatable production.
PROJECT SNAPSHOT
INDUSTRY
Automotive
APPLICATION
Anti-Lock Brake Sensors
CAPABILITY
Furnace Brazing
OBJECTIVE
Reduce Cost + Improve Production Efficiency
THE CHALLENGE
A NEW PRODUCT NEEDED A PRODUCTION-READY PROCESS.
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A Fortune 500 automotive manufacturer developed a new line of anti-lock brake sensors using a two-piece 304 stainless steel design.
As the product moved toward full production, the manufacturer needed an efficient method for joining the two components while maintaining the quality and consistency required for an automotive application.
The solution also needed to support the company's key production objectives:
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Reduce manufacturing costs.
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Maintain consistent assembly quality.
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Maximize production efficiency.
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Meet scheduled deliveries.
THE ROGERS METAL SOLUTION
FROM DESIGN SUPPORT TO PRODUCTION
BRAZING.​
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Rogers Metal Services worked with the manufacturer to develop a brazing process designed around the component, production requirements, and cost objectives.
By combining brazing expertise with practical production experience, Rogers established a repeatable process capable of delivering consistent assemblies efficiently and on schedule.
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PROCESS DEVELOPMENT
Developed a brazing process specifically for the two-piece 304 stainless steel sensor design.
BRAZING OPTIMIZATION
Established repeatable brazing parameters to produce strong, consistent joints while controlling processing costs.
PRODUCTION INTEGRATION
Created an efficient production approach capable of supporting the manufacturer's required volumes and schedules.
QUALITY CONTROL
Implemented controlled processing and inspection requirements to maintain consistent assembly quality.
THE RESULTS
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A BRAZING SOLUTION BUILT FOR PRODUCTION.
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The Rogers Metal solution addressed more than the brazed joint. It helped the manufacturer establish an efficient production process for its new anti-lock brake sensor line.
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REDUCED MANUFACTURING COSTS
A cost-effective brazing solution helped lower the overall cost of producing the sensor assembly.
CONSISTENT ASSEMBLY QUALITY
Repeatable processing provided dependable joint quality across production quantities.
INCREASED PRODUCTION EFFICIENCY
An optimized process improved throughput and supported efficient ongoing production.
