Engineering a Fix — Saving an Auto OEM $300 Per Vehicle with Smarter Material Conditioning
CHALLENGE
Our customer, a large OEM, was experiencing manufacturing defects tied to the low-voltage insulation paper used in the stator at their Michigan production site. The material frequently tore or absorbed moisture, disrupting insertion and assembly.
To resolve the issue quickly, the OEM had begun substituting with a laminate material from overseas - a solution that worked but came with a steep price: an additional $300 per vehicle. With long term cost concerns mounting, they needed a more sustainable solution.
SOLUTION
EIS partnered with the insulation paper manufacturer and worked closely with the OEM’s engineering and production teams to pinpoint the root cause. The issue stemmed from excessive moisture absorption and improper handling practices, both of which were amplified by environmental conditions at the Michigan facility.
Our team guided the OEM on proper storage and handling of the material, while also working with the production team to optimize machine settings for both auto and wire insertion. In addition, we educated them on adapting to climate-related challenges and recommended procedural improvements to reduce sensitivity to humidity and minimize surface damage.
This collaborative approach eliminated the need for expensive material substitution and empowered the team with a process-driven fix.
RESULT
The OEM successfully reverted to using the original insulation material, which was a higher performing material, in their stator production, avoiding the additional cost of switching to any alternate material. The fix coincided with a planned retooling of their Michigan production line, allowing the team to integrate the process changes efficiently across operations.
Key outcomes:
- $300 saved per vehicle
- Reduced material failure
- More efficient stator manufacturing
- No need to rely on more expensive alternative materials
This success story demonstrates how EIS combines technical insight and supplier alignment to turn complex material challenges into cost-saving, scalable solutions.
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