Automotive Steering Column Assembly
The manufacturer was using an 8 x 45 standard duty phosphate coated Coiled Pin from a competitor. The customer was experiencing high levels of failures and scrap during the installation process due to the high insertion forces needed to assemble the pin within the application. As well as the high scrap levels, the customer was also experiencing poor productivity due to increased down time.
Due to the fact that this was a mature design, the hole sizes could not be changed as it would have cost too much to modify all of the involved parts and perform revalidation tests. Also the customer was using automated assembly equipment that had been set up to operate within a certain range of force in order to ensure that the housing would not be damaged by application of too much load, but ensure the retention of the pin.
Once assembled there was very little load actually applied directly to the pin.