| Case Study : Marking on electronic sensors used in automobiles |
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From its UK headquarters and factory in Diss, Norfolk, Hamlin Electronics manufactures electronic sensors for some of the world's premier automotive OEMs. Matt bailey investigates how, faced with increasingly stringent marking and traceability standards, the company has successfully adapted its processes and techniques to meet the demands of its client base. The traceability challenge Only a few years ago motorcars required few if any on-board electronic sensors. Today, with the advanced electronic management systems found within even the most basic models, many have tens and sometimes even hundreds of sensing devices located throughout the vehicle. "Modern automotive systems use an increasing amount of input data, so they need more sensors to provide that information," explains Hamlin production engineer, Brad Miller. "In recent years our sensor development and production operation has expanded rapidly. Manufacturing components for a first tier supplier of fuel tanks to the automotive sector has brought particular challenges." Many manufacturers producing components for the automotive sector will confirm that a marking and traceability capability is becoming essential, especially with some of the leading auto OEMs increasingly determined to pass warranty costs back to the supplier of a failed part. According to US-based business consultancy AMR Research Inc, cost and productivity initiatives by the world's vehicle manufacturers aim to shift up to 45% of warranty liability to suppliers that have a 'prime part' named in any component failure. The AMR report also claims that a fifth of production-line part problems go unreported because of a lack of factory floor visibility. Hamlin's proximity sensor production volumes have increased requiring a more automated marking process. The growing throughput has introduced fresh challenges. "Originally we used inkjet marking," says Miller, "which had some major drawbacks and limited suitability for the variation and volume of sensors we were making." At the outset Hamlin marked the sensor housing, but the customer subsequently requested different colour housings, which demanded alternative colour inks and printers. The first part of the solution was to mark the other end of the sensor: the connector. As a result, the marking issue became a much simpler problem to solve, as the connector is common to all of Hamlin's different sensors, irrespective of colour or purpose. This allowed the company to source a universal solution, including the possibility of an impact system thanks to the connector's reduced sensitivity in comparison with the sensor. As well as being easy to read, the mark also needed to be permanent. Many of the Hamlin sensors end up in 'under-bonnet' locations where they can be subjected to high temperatures, fumes, dirt and moisture. In such rigorous operating environments, product marks needs to be legible for the long-life demanded by the customer. Miller's research into a more durable mark began on the internet, where he came across the website of Technifor Ltd, the UK subsidiary of the global industrial marking and traceability specialist. "After we made contact I sent Technifor UK some samples to mark using their micro-percussion marking system," he says. "When we got them back I sent them to our customer and they were approved almost immediately." The first fully integrated Technifor marking system was installed and operational by January 2005. Just a few months later, the company had three in place. One of the primary products marked at Hamlin is a sensor that is used as part of an automotive fuel system. The sensors are required to be 100% tested on equipment that was developed by Hamlin, which now also incorporates the Technifor marking system. Once the sensor has been placed in the test head, the test cycle begins. On completion, the printer is signalled to mark the product identification number, batch number and date codes on the connector. At the end of the test, and once the sensor has completed the routines successfully, a pass message is printed. If any part of the test is failed, a corresponding code is printed instead. This helps to track errors and instigate any necessary corrective action required to minimise scrap. These days, Hamlin produces, tests and marks tens of thousands of sensors every month. "Because the inkjet marking system requires consumables which are relatively expensive, as well as routine daily maintenance, there was an added cost saving," concludes Miller. "The Technifor system, by contrast, is very reliable and requires almost no maintenance and no consumables. Overall it's just a much more suitable and reliable process."
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