As automakers’ margins continue to be pressured by various economic and political factors, self-tapping fasteners, such as TAPTITE PRO®, can provide substantial savings and elevate some of the pressures. In a study completed in 2012 by USCAR, it was found that if an automaker transitioned their entire fastener production to TAPTITE® products, they could save approximately $800 million (or $1.05 Billion when adjusted for recent inflation) per year.
During the research phase of the study using proprietary studies, USCAR found that other studies indicated that at least 30% of all machining energy used in a “typical” powertrain (engine and transmission) is consumed in both the drilling and the tapping of holes. Further studies found that by switching to products such as TAPTITE PRO®, automotive companies can realize savings between $.07 to $.09 (or $.09 to $.12 when adjusted for recent inflation).
Figure 7.2 from the report “Machining Elimination through Application of Thread Forming Fasteners in Net-Shaped Cast Holes” (USCAR) Project No.: FAS 1005) illustrates how the use of TAPTITE PRO® eliminates 4 total steps from the manufacturing process to help reduce both plant energy consumption, as well as realize the previously mentioned $.09 to $.12 cost savings per fastener.
Additional benefits discovered in the study include:
- Cross-threading is not possible resulting in higher productivity, improved quality,
- less warranty concerns
- Stronger internal threads due to the cold flow work hardening during thread
- Formation
- Elimination of chip handling and reprocessing
- Elimination of fastener locking features like lock washers due to the superior
- vibration resistance of the lobular design, also resulting in less warranty calls for
- squeaks and rattles
- Environmental improvement due to elimination of machining coolant
- Enabler to lightweight material substitution (CAFÉ improvement) through
reduction in cost differential between lightweight materials (Al. and Mg.) and ferrous materials.
The report concluded their studies by stating “In summary, when fully implemented, the application of thread forming fasteners would result in the elimination of machining centers for drilling and tapping, gaging stations, automated stations for probing and cleaning, material handling between stations, coolant systems for machining centers, chip handling and recovery systems, significant manufacturing floor space, and associated building facilities like HVAC, lighting, and human necessities and conveniences.”
To review and download the USCAR report please click here ->
While it has been known in the industry that self-tapping products such as TAPTITE PRO® have been key to realizing cost savings in the supply chain, USCAR has been able to quantify these savings in their report. During a time when supply chains are being consistently strained and the price for raw materials, parts, and labor keep increasing, TAPTITE PRO® and other REMINC / CONTI products can be a powerful tool in helping with cost savings and margin protection.
In addition to cost savings, the same report found that total direct energy savings is, 4.32 trillion btu/year by switching to products such as TAPTITE PRO®. For more detail on how TAPTITE PRO® is helping automakers reach net zero carbon goals, refer to our article here ->
The combination of cost and energy savings is the perfect combined solution for automakers looking to reach both financial and environment goals in a challenging new environment.
Qualifications of the research team via the report:
“7.3 Qualifications and Resources
The Project Director is William Charron. He has over 34 years of experience at Ford Motor Company, primarily in powertrain operations serving in many engineering functions. He has extensive experience in machining lines and project management for program launch and advanced manufacturing development. He has specific experience in leading fastener development projects at USCAR. He has both technical and management masters degrees.
The Principle Investigator is Todd Cleaver. He retired from Ford Motor Company after 35 years and launched Tech Knowledge, a manufacturing development technical services company. His Ford experiences were in casting and machining with over 20 years in management of advanced engineering projects. He has specific experience in both casting and fastener development projects as well. He has a bachelor’s degree in engineering and a master’s degree in management.
The test laboratory supervisor is Adrian Cockman. Adrian has 30 years of experience in Ford Motor Company all focused on fastener development and application. He supervised all fastener testing for this project and played a key role in the analysis of the data. He has a degree in engineering.
The project team consisted of representatives from the US automobile industry, fastener manufacturing industry, the casting supply base, and trade organizations.
The project team has access to a 12 boss die casting die suitable to deliver all cast nuts and washers required for the work described in the work plan. Sufficient production capacity was available in local die casting and machining job shops to assure quick delivery of all cast nuts and washers required.
The Ford Fastener Laboratory performed all fastener testing. It has all the latest state- of-the-art fastener testing hardware and instrumentation including RS technology load cell assessment equipment, Micro Control MC900 data collection systems, a broad spectrum of bolt drivers, transducers, etc. and an experienced staff. “