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Automotive / SUV / Truck Sub-assembly

As an important part of our synchronous contract-manufacturing-support for automotive and truck original equipment manufacturers (OEM), Comprehensive Logistics (CLI) builds a variety of highly complex sub-assemblies at multiple manufacturing-support operations. We perform sub-assembly for:

Our synchronous sub-assembly services are engineered to accommodate the most complex product configurations.

We have excelled at the most intricate sub-assemblies, ranging from three to almost 100 build variations. CLI builds more than 2.5 million combined automotive, truck and SUV sub-assemblies annually including electric vehicles. Depending on the type of sub-assembly, we use a variety of assembly methods, including:

  • Fully automated builds using robotics and programmable logic controller systems.
  • Conveyor built, which combines manual and robotics assembly, positioning, torque monitoring, and programmable logic controller systems.
  • Sequenced, step-by-step manual station builds.

How does our sub-assembly process work?

  • A pull signal from the OEM initiates the integrated multipart pick processes.
  • Fully integrated ERP and line controllers tie line-side parts location, consumption, and error-proofing into a synchronous, transparent system.
  • Disciplined process controls ensure compliance with stringent quality standards.
  • Error-tolerance detection adheres to OEM-defined standards, including tolerances as small as 40 microns—a length smaller than the diameter of a human hair.
  • Completed sub-assemblies are off-loaded and placed into specially designed reusable containers for lineside delivery at the OEM’s assembly plant.

Error Proofing

All of CLI's synchronous sub-assembly operations adhere to a precise error-proofing process, which includes these tools and techniques:

  • Scan guns, pick lights, and light screens ensure that correct parts are configured and installed accurately every time.
  • Vision systems, laser-placement guides, and proximity sensors detect correct part presence, location, and orientation.
  • Predictive capability uses statistical process control software to collect data.
  • Torque and torque angle readings are tied to final assembly barcode labels.
  • Assembly tools are calibrated once per shift.
  • Master part gauges use digital probes to allow for adjustments.

Through millions of builds involving multiple variations and meticulous error-proofing, CLI has perfected our sub-assembly processes to ensure the highest quality standards and precision for automotive and truck OEMs.

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