Enhanced die casting supply chain

Enhanced die casting supply chain

When deliveries of a part used in thousands of Honda SUVs became challenging, Piolax USA examined its entire supply chain to find the cause of the problem.

All indications pointed to the die casting part itself as the issue, one Piolax might have to accept—until alternative suppliers recommended Dynacast.

Piolax USA produces a range of metal and plastic automotive components that cover the whole vehicle, from clamps and harnesses to powertrain and fuel components.

"We're fully dedicated to automotive," says Josh Miller, Purchasing Manager at Piolax USA.

This is no exaggeration. Its Japanese-owned parent company, Piolax Incorporated, is a powerhouse in the industry. Currently in its 85th year of operation, it's publicly traded on the Tokyo Stock Exchange and serves an incredibly demanding client base.

"Nissan is our primary customer, and we are a tier-one supplier for Ford, Honda, Toyota, and GM," Miller notes. The relationships extend to many of these brands' other suppliers as well.

With the global industry relying on them for components, Piolax—which stands for 'pioneers of elasticity'—requires a supply chain as adaptable as its name implies.

Supply chain audit

A decade ago, the manufacturer based in Canton, Georgia, initiated a project with Honda. "The application involved a tie-down assembly," Miller explains. "It enables users to firmly secure luggage or any items in the SUV cargo area."

For years, the project progressed routinely, and Piolax received the product only after it was die cast, sanded, polished, and plated. However, over time, the part was incorporated into more platforms, models, and configurations, which led to increased volumes—and challenges with on-time delivery.

To discover the root cause of the issue, Piolax visited each supplier involved in the component.

"We realized that most of our suppliers—the plater, the polisher, and the abrasive blaster—were world-class," Miller states. "The actual manufacturing, specifically the die casting of the hook, was the weak link."

Pressed for time and quality

Initially, Piolax used a die caster from neighboring Alabama for the component production. However, as the project expanded, the supplier became a bottleneck—especially with the levels of quality and aesthetics required for the part.

"For chrome-plated die casting components, everything must come together precisely," says Brad Doornbos of Dynacast. "Tooling, tool temperature, fill rate—every condition must be perfect."

If not? "If the part emerges from the tool with any flaw," Doornbos explains, "the chrome plating will highlight and magnify even the smallest surface defect."

This results in added delays, costs, and waste, whether through additional sanding and polishing or scrapping the cast components before shipping. Either way, Piolax found the problem.

Confidence and capability

For the latest version of the component, Miller and his team consulted other suppliers for advice. They inquired, "Who would you recommend that can undoubtedly produce a high-quality component visible to the end customer?"

"The first recommendation was Dynacast," Miller notes.

He included a visit to Dynacast's Peterborough, Ontario plant in his audit. That visit confirmed his suppliers' belief in Dynacast's ability to meet Piolax's standards.

"It was evident they had experience with similar projects. The appearance issue with the previous component didn't intimidate them; it was well within their capability," Miller explains.

His discussion with Dynacast's engineering experts reinforced his perception. After that visit, Piolax awarded the new project to Dynacast—however, that wasn't all.

"The professionalism, organization, and precision they exhibited made it clear they knew what they were doing," Miller recalls. As a result, he canceled his prior project with another die caster and shifted it to Dynacast.

"Timely delivery, quality, communication, and pricing were challenging with our former supplier," Miller says. "These are the four key aspects that must be strong for us and our clients, and those were the factors I knew Dynacast would deliver on."

"I was confident that Dynacast would be a reliable supplier for Piolax. Not just now, but also a partner we can grow and advance with in the future." - Josh Miller, Piolax