Production of complex decorative parts: Creation of DNH automotive dashboards
For the production of complex plastics decorative parts for one of our customers in the automotive industry, we set up a complete solution from plastic injection to final assembly, while guaranteeing the quality of the parts produced and production quantities for mass-produced vehicles. With its innovative production processes, the quality finish of our paint lines (less than 5% scrap) and its reduced ecological footprint thanks to its optimized logistics loop, this project is proof of all the know-how and values of the DEMGY Group.
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The project : Complex decorative parts for automotive interiors
One of our automotive customers was planning to produce complex decorative parts for vehicle interiors, notably for the Peugeot 3008 and 5008 models. Chromed on the visible parts, these parts also needed to be welded to guarantee consistent quality.
What were our customer's challenges?
- A production site based in Eastern Europe
- To control the entire manufacturing process in-house
- Guaranteeing the quality and reliability of large-scale parts production for mass-produced vehicles
An innovative, tailor-made solution
DEMGY Romania proposed a complete, integrated solution, to carry out all stages of the project at the two production sites:
- Plastic injection and selective chroming : we integrated a plastic injection process
with selective chroming. This process enables us to chromeplate only the visible parts of the parts, while preserving other essential sections for subsequent assembly. This technique is essential to the success of ultrasonic welding assembly, as any presence of chromium would have prevented effective welding. - Innovative ultrasonic welding assembly : we proposed and implemented a technique enabling specific parts (such as the meter's chrome-plated “ring”) to be welded irreversibly, with no mechanical play, thus ensuring consistent, long-lasting quality.
- New robotized paint line: for this specific project, a new fully robotized paint line was installed. This line reduced scrap rates from 30-40% to less than 5%. This is proof of DEMGY Romania's ability to provide solutions tailored to each project, while maintaining the efficiency of its processes.
- Chromium plating line: the chromium plating operation is carried out at our second production site in Romania, DEMGY Deva, which reduces the time and cost of transporting parts.
Challenges encountered during project implementation:
- Development of a new robotized painting line to meet the challenges of chromium plating the parts to be produced without damaging the assembly.
- Stabilization of new painting and chrome-plating processes with maximum reduction of production defects (scrap rate below 5%).
- Production demand higher than initially planned (+10,000 units per week)
Benefits for the automaker customer
The main advantages of our customer paths
Total control of production processes, avoiding the need for subcontracting and reducing the risk of defects.
Significant reduction in scrap rates, improving overall efficiency and cutting costs.
High production capacity to meet peak demand, ensuring uninterrupted deliveries.
Optimized logistics loop with the customer, enabling efficient return of empty bins for immediate reuse, thus contributing to a reduced environmental impact.
Summary of this project to create a multi-technology part for the automotive market
By integrating new production processes, DEMGY Romania not only overcame the initial challenges, but also enabled the customer to stabilize its operations and maintain high quality over large production volumes. This success has strengthened the customer's confidence in our capabilities and opened the way to new opportunities for collaboration, particularly in similar markets. Our new decorating processes enable us to offer solutions for the market of decorated interior parts for the automotive sector, from light vehicles to heavy goods vehicles and even agricultural vehicles.