Toolmakers are not just interested in meeting the customers’ needs and requirements, they strive to exceed them.
With SUPERB’s in-house development and assembly, high speed progressive carbide dies, in die staking and welding, in-house heat treating, and all tool steel and carbide, toolmakers work closely with customers. Focusing on the customers is critical because it allows the toolmakers to assist customers one-on-one with new projects or how to save money on existing projects.
The best value proposition comes when both the product design and process design are optimized to deliver value.
The SUPERB engineering team works alongside our customers to optimize product design to meet all performance criteria while assuring compatibility with efficient manufacturing processes. By using this collaborative process, value is engineered into the product DNA to ensure global competitiveness. This process often reduces total product cost by over 50 percent.
Problem: The existing die cast lock system for this truck cap handle was costly and cumbersome. The die-casting added weight to the vehicle and was susceptible to corrosion.
SUPERB Solution: SUPERB engineers redesigned the lock system to include a field activate-able integrated e-lock system. The die cast components were replaced with high strength engineered polymers.
Result: A patented high strength lightweight lock system with integrated e-lock that can be cost effectively mass-produced.
Problem: A major truck cap manufacturer needed a universal clamping system to reduce the number of SKU’s required to fasten truck caps to beds. The old system required several dozen SKU’s to cover the product offering.
SUPERB Solution: SUPERB product and process engineers worked with the customer’s product engineering group to develop an esthetically pleasing modular clamping system where one size fits all.
Result: The number of SKU’s for the clamping system was reduced to one. The cost per unit was reduced. The product styling was improved from a “hardware look” to a sleek stylized OEM automotive look.Keyless Entry—No wire. No mess. No installation.
Problem: Dealers complained about installing a 20-foot wiring harness to power the remote to open a Tonneau cover on a pickup truck.
SUPERB Solution: A newly developed SOL-A-RAY technology that provides power with a highly flexible solar cell.
Result: SOL-A-RAY is a patented, esthetically pleasing, self-adhesive solar cell that powers not only the remote lock but also a LED lighting console. This upgraded keyless entry comes direct from the factory and increases the customer’s profits, while giving the consumer a better product.
With Poka Yoke mistake proofing, the fully automated robotic, semi automatic, or manual assembly cells are an asset to all customers who receive parts with an unbeatable value that have been assembled by the fast, efficient, and experienced SUPERB team. SUPERB stocks components for customers so that custom manufactured assemblies can be shipped directly to the customer on a just-in-time basis.
SUPERB engineers review product and process requirements and then design a Bihler process solution which will yield the most cost effective manufacturing process. The ability to process a strip of material or individual components through a series of asynchronous steps in one integrated process ensures maximized efficiency and product repeatability. These process steps may include progressive stamping and bending of metal, followed by operations which would normally occur in a separate process—tapping threads, welding components, inserting plastic parts, and other assembly operations.
Bihler enables all of these steps to be performed in one process from raw material to finished sub-assembly at higher speeds than conventional automation because the process flow has not ben interrupted. This significantly reduces the machinery footprint, reduces labor cost, and work in process, all leading to a cost competitive product.