The Opportunity

Our automotive IP / consoles customer has a very wide range of small assemblies, that together form full instrument panels and consoles for an automotive OEM.

A critical part of the assembly process is a 'No Faults Forward' methodology. When a single missing part can cause customer plant rejections - it is imperative that each assembly is right first time!

The huge variety of designs within the vehicle generates a massive amount of potential for failure of the process so it is essential that they are stopped at source and prevented from escaping the assembly process.

The Solution

Using a standard bench format, in a range of sizes, we design and manufacture NFF sub assembly systems equipped with Torque driver(s), process control HMI assemblies, bar code scanners, sensor IO, bar code printers and a variety of materials and techniques to engineer a process that cannot allow a faulty part to escape.

Part sensing, clamp engaged sensing, DC tooling feedback is used to control the assembly process at each step - with the process moving forward only upon receipt of an appropriate sensor confirmation, synchronised with operator instructions via the assembly process. 

The examples below use a Desoutter Infinity HMI for process control and monitoring of IO via ethernet from the remote panel, which is fully integrated into the customer plant for traceability. The result is a fully Poka-Yoke'd assembly process, to survive the rigours of 24/7 use.

car assembly


The Benefits

  • Lower operating costs
  • Improved worker safety
  • Reduced factory lead times
  • Ability to be more competitive
  • Increased production output
  • Consistent and improved part production and quality
  • Optimal utilization of floor space
  • Easy integration
  • Maximized labour
  • 24/7 non stop production with minimal maintenance
iac logo

With more than 160 years of automotive interiors expertise, International Automotive Components (IAC) is a leading global supplier of automotive components and systems. We bring added value, service, and success to our customers, investors, and employees, reinforcing our quality, value, and technology.


No fault forward

Trouble free production systems ensuring issues and faults are identified when and where they occur


Traceability systems

Tracking parts and components throughout the process

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Poka-Yoke assemblies

Eliminating product defects by preventing, correcting, or drawing attention to human errors as they occur

Talk to us

Contact us today and we can discuss your project needs.
Request call back

Talk to us

Contact us today and we can discuss your project needs.
Request call back


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