PHB Quality Systems

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case study
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the problem
A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.
the solution
The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
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PHB promises delivery of quality diecast, fabricated, rubber, and plastics products through process development and advanced product quality planning (APQP). We use CCM software and precision measurement, 1st article inspections, in-process inspections, and final inspections to control quality through the entire production process. Our quality planning experts use the core tools – APQP, FMEA, PPAP, MSA and SPC to ensure production is capable of delivery of a quality product.

ISO 9001:2008 certified / TS16949

PHB Quality Systems place emphasis on customer satisfaction and the foundation for providing exceptional products that meet specifications and exceed customer expectations. As a global manufacturing company and supplier, PHB is certified for the International Standards System TS16949 which means we continually align our manufacturing quality and organization at the highest levels.

PHB quality system capabilities

PHB has the facilities to 3D scan and reverse engineer, with DMIS based DCC CMM technology allowing for rapid identification and mapping of all product characteristics. By also verifying product quality via x-ray, spectrometry, particle inspection, vacuum decay and mass flow testing, and vision inspection with thermal imaging, you can expect the highest possible quality end result.
PHB reduces variation in the manufacturing process to control costs and reduce rejects with Six Sigma activities. Black belt and Green belt projects drive improvement through lean activities, sampling and numerical evaluation of metrics, design of experiments and variation studies. PHB Quality systems promote proactive defect prevention rather than reactive defect detection throughout the entire corporation.

cognex vision system

PHB utilizes a state of the art vision system for verification and optimization of certain common vision tasks, such as checking for the presence or absence of parts and features, inspecting and identifying parts and detecting defects. PHB has manufactured die cast parts that can function only if every intricate component has been included through the casting process. PHB can promise the highest level of quality and part performance for industries such as pharmaceutical, automotive, healthcare, aerospace and consumer products manufacturing.

The FARO Edge ScanArm®

In order to create the highest quality castings and tooling, PHB has acquired a new, non-contact portable laser line scanner. The laser/scanner is used for product development, inspection, and quality control, and offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling. Some of the FARO Edge ScanArm® capabilities are:

  • Non-contact inspection of parts, castings and tooling
  • Direct to CAD comparisons
  • Assist in reverse engineering
  • Compatible with Polyworks Inspection software
Our customers demand cost effective components with the highest levels of quality, reliability and on-time delivery. PHB is committed to these requirements.

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