AUTOMOTIVE FASTENERS
Bespoke fastening
Faltec Europe employs TR Fastenings
to deliver competitive fastener supply and tooling solution
T he automotive industry
is a vital part of the UK
economy. The industry has
an £82 billion turnover (plus
£20.2 billion value added). More
than 30 vehicle manufacturers
in the UK rely on a complex
network of suppliers - a single
car has around 30,000 parts.
In the UK there are also
around 2,600 component
manufacturers supplying parts
directly to OEMs.
The automotive industry is
a vital part of the UK economy.
The industry has an £82 billion
turnover (plus £20.2 billion
value added). More than 30
vehicle manufacturers in the
UK rely on a complex network
of suppliers - a single car has
around 30,000 parts. In the
UK there are also around 2,600
component manufacturers
supplying parts directly to
OEMs.
The automotive industry
has a traditional tiered supply
chain (Tiers 1, 2 and 3, with
Tier 1 feeding directly into
OEMs), but some lower tiered
component manufacturers, such
as TR Fastenings (TRF), are
challenging the existing market
structure, taking a much larger
role in innovation and Tier 1
production-line support.
Faltec Europe required a
bespoke fastening for a new
major programme it had
recently secured with a key
global OEM. The trim product
to be developed was an injection
moulded exterior trim part for
a new vehicle due for release in
November 2019.
Faltec Europe Ltd, part of the
global Faltec Group, is a worldclass
manufacturing company
and an accredited Tier 1 supplier
to the automotive sector. Faltec
Europe manufacture many of
the interior and exterior vehicle
trim products you see every day
on the most popular cars on UK
roads.
Faltec’s European division
produces over 300 car products
from front bumpers to radiator
grills, roof mouldings, door
mouldings, door sashes, roof
finishers, weather strips and lots
more.
Faltec’s business model
is based on being robust,
flexible and adaptable to meet
customers’ requirements within
a fast-changing market and
global economy. This case study
is a true demonstration of that
ethos.
A late design change to
improve the fit of the part to the
vehicle required the attachment
of a strengthening support via
a Peel type rivet. Peel rivets are
a type of blind rivet designed
to offer improved support in
brittle, soft or ductile materials,
applicable to the vehicle trim
products in this project.
Fired using bespoke
tooling, the head of the Peel
rivets explode and become
mushroom-shaped as they enter
the moulding. This creates a
large blindside bearing surface,
significantly reducing the risk
of the rivet sinking into or
breaking the moulding.
TR Fastenings (TR) and
Faltec are both active within the
North East Automotive Alliance
(NEAA) network. Following a
successful pitch, TR Fastenings
was appointed By Faltec as the
company’s provider.
APPROACH AND SOLUTION
As a global specialist in
the design, engineering,
manufacture and distribution
of high quality industrial
and Cat C fastenings, TR was
able to identify the original
equipment source and submit
a competitive supply solution.
TR is renowned for working
with clients from design
table to production line to
achieve innovative, effective
and efficient solutions. The
TR product and tooling for
this project offered a robust
solution and would guarantee
efficient production - this
secured the initial business.
Not only could TR provide
the specific fastener solution,
but in this instance, it was also
able to supply bespoke tooling
compatible for the fastener.
The tooling required a bespoke
rivet gun that would not only
automatically fire the rivets
into the moulding to be joined,
but also have capability to
apply rivets in a fast production
environment.
PROJECT CHALLENGES
Timescales were challenging
for both parties but with close
co-operation qualified parts
were supplied along with
tooling for development and
ongoing production, both being
delivered on time. Not only did
TRF have to supply production
intent rivets in a short
timescale but also the gun was
ordered late due to last-minute
design changes, requiring 24
hour delivery.
The late design change by
the OEM required special rapid
response by TR and Faltec.
TR was able to take the lead
on supplying fast-production
intent rivets and tooling in a
very short period.
Greg Lynch, Automotive
Business Development Manager
at TR said, “Perhaps the biggest
challenge came with technical
advice and training. TR had
to ensure correct and safe
operation of the rivet gun.
Due to its bespoke nature,
Faltec staff responsible for the
18 Issue 2 2020