Decorative Tailpipes Development Case for BYD

In April 2015, we received a request for assistance from a BYD partner. A BYD part they had taken on was scheduled for mass production in just two months, but neither its product quality nor production capacity met the mass production standards. BYD's procurement staff, together with the original supplier, communicated with our company to seek a solution. Hexin's technical engineers analyzed and assessed the current situation, identified the key challenges, formulated a corresponding preparation plan, and confirmed that we could meet the mass production requirements.

The project was initiated in April 2015, and the development of rear bumper decorative tailpipes was launched. We improved the problematic molds, established a dedicated assembly production line, and completed verification work covering quality, production capacity, performance and other aspects. The project successfully passed the approval process before the new vehicle's launch in June 2015, and we obtained the permit for mass production supply.

During the development process, process simulation and analysis were used to solve the defect of material cracking, increasing the qualification rate to 99.7%. The independent development of assembly robot workstations effectively addressed the issues of insufficient production capacity and unstable product quality. Additionally, the project resolved the quality defect of product surface scratches, achieving zero defects in product delivery.

Our decorative tailpipes are applied to BYD models including Tang and Song.

* Design and manufacturing of tooling and gauges;

* Design, development and manufacturing of special equipment for production capacity improvement;

* Various product performance testing and verification (including welding sensitization testing, welding strength testing, corrosion resistance testing, air tightness testing, material physical property testing, product precision section testing, etc.);

* Implementation of various PPAP requirements, etc.

The development cycle was shortened to 2 months to realize mass production, and the production capacity met the maximum monthly demand of 15,000 units (achieving 150% of the production capacity target). The qualification rate for cracking defects was increased to 99.7%, and zero defects were achieved in delivery. This resolved the risk of new vehicle launch delays due to mass production supply shortages and enhanced Hexin's overall emergency response capabilities.