Center Console Assembly

The Challenge

A major automotive OEM approached GLA seeking help in replacing its existing supplier who was struggling with quality and delivery of IP Panels (center consoles). Immediately GLA begin working on a proposal that integrated design features in the process and equipment to prevent the chronic quality problems that plagued the current supplier. In April 2007, GLA was awarded the contract to assemble the center console radio and heating control panels for the 2008 Honda Accord. Full production of the 2008 Accord was scheduled to begin in August 2007, leaving GLA less than three months to implement an assembly line for new model launch demands in July 2007. The center console assembly consisted of producing more than 80 unique assembly configurations and combinations. While many of the configurations were substantially different, some configurations varied only by very slight color or program changes often difficult to differentiate. Critical control of fastener torque values for each assembly was also an important requirement.

How GLA Addressed the Challenge

The GLA production system utilized five (5) DC nut runners and four (4) one-dimensional and two-dimensional scanners. Each assembly was assigned an individual assembly number at GLA. Each supplier component part number of each assembly component was then assigned to the respective GLA assembly number. The GLA assembly number was later linked to the VIN of the specific vehicle by Honda at installation. If the supplier part number did not indicate the correct color, type, and programming of the assembly number part, the system would not allow that supplier part to be assembled and GLA’s system would not permit continued processing of the assembly. A batch count technique was also used at each torque station to ensure that proper torque requirements were met on every assembly. The GLA production system does not permit the advancement any assembly that has not met the correct number of passing torque values.

The Benefits of the GLA Solution

GLA offers Honda the ability of full traceability of parts through its scanning system. GLA produces more than one thousand center console units per day. The system is flexible, ergonomic and highly efficient.