Automotive key manufacturing: from injection to automated assembly
The major challenge in the manufacture of automobile keys lies in the need to combine two requirements: rigorous dimensional precision and impeccable appearance quality.
DEMGY Atlantique meets this challenge by combining technical and appearance parts. Technical parts require high dimensional precision, while appearance parts are judged primarily on their visual finish. These two skills enable us to manufacture car keys that are beyond reproach.
Car keys are not only functional components, but also essential communication elements for automakers, playing a vital role in the user experience and brand perception.
An assembly process that meets technical challenges
Technical complexity stems from the hybrid nature of keys, which require both tight tolerances and a perfect visual finish. Manual processes, previously used in semi-automated assembly, posed repeatability and quality challenges. Even minimal human intervention could lead to variations and defects in production, making it difficult to achieve the required dimensional tolerances and appearance quality.
DEMGY Atlantique's automated assembly solution
To meet the stringent demands of customers in the automotive sector, DEMGY Atlantique designed and implemented an automated assembly solution. Automated key assembly guarantees process repeatability and consistent quality. Integrated detection systems (Poka-Yoke*) at each stage of the assembly process ensure that each operation is carried out correctly, and eliminate faulty parts.
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*Poka-Yoke is a technique used in production to avoid human error. It involves designing devices or processes to prevent errors before they occur.
This automated assembly solution enables total traceability thanks to unit identification by QR code. Each part produced can thus be traced throughout its life cycle, enabling a production batch to be quickly traced in the event of a complaint.
Results of key assembly automation :
Improved quality : automation helps reduce production defects. The rate of defective parts has fallen to between 10 and 15 PPM (parts per million), mainly due to technical defects, which represents a very high level of quality in the automotive industry.
Cost optimization : automation enables a significant reduction in assembly cycle times, and thus in production costs.
Production capacity: the automated assembly solution meets the customer's capacity requirements, with production of up to 140,000 parts per week.
The circular Multiplasturgy® offer: the automation solution by DEMGY Atlantique
The complete assembly automation solution implemented for the production of automotive keys meets all the technological, economic and environmental challenges of the automotive sector.
By combining dimensional precision, appearance quality and total traceability, DEMGY Atlantique improves product quality and optimizes production and logistics costs. DEMGY Atlantique thus strengthens its competitiveness on the international market thanks to its circular Multiplasturgy® concept: the new assembly automation solution.