Eight Million Brake Light Switches per Year
The production of eight million brake light switches annually is subject to its own set of priorities. Flexibility is less important here than other factors such as maximization of output and reliability of process.
When a car manufacturer nowadays relies on just one provider for the mass production of a component, that amounts to both an honor and a responsibility for the chosen supplier. Body Control Systems (BCS), a subsidiary of worldwide automotive supplier TRW, is responsible for the production of eight million brake light switches annually for the Volkswagen Group. As a global company with more than 4,000 employees in 12 countries, BCS supplies all the major automotive original equipment manufacturers worldwide and therefore has the expertise and organizational structures necessary for such operations.
Close to the Zero-Fault Production
After removal, the six-axis robot places the finished molded parts into groups of eight in a workpiece carrier. A linear system then picks up the brake light switch- es and passes them to the subsequent work stations for the prescribed quality checks, including a continuity test and measurement of the length of the contact pins. The tested brake light switches sub- sequently leave the plant on small load carriers that have been already placed in position. The plant operates in three shifts around the clock.
“Over 10,000 brake light switches leave the production cell per shift. With only two to three defective parts per 10,000 units, we are close to having zero-fault production”, summarizes Jochen Ley. “In addition, the plant meets all of our re- quirements, producing parts reliably, quickly and economically. With the large- scale production of eight million switches annually to contend with, we could not have it any other way.”