After the completion of two large manufacturing projects (both concerning automated production of vibration absorbers) we are now intensively preparing the third project of this size: a largely automated series production of rubber hangers for the suspension of exhaust systems that will be used in a new BMW car model.

Winning this hanger project was of high strategic value for WEGU. It allowed us to prove that in Kassel it was possible to manufacture even rubber hangers of lower complexity at competitive prices. Key factors of our success were both our technical design and the expected cost reduction through automation.

We are now facing the challenge of taking our technical solution to mass production within the next few months. The parts have to be validated through numerous tests in our hydro-pulse test bench. Such a test can take up to 2 weeks per part. In parallel, we need to prepare the intended manufacturing techniques which involves both the construction of required tools and the selection of appropriate machinery.

For both problem areas our project team will still have to solve a lot of details before the ramp-up of series production can start.

Figure 1: Exhaust Hanger for BMW Mini including metal support