ENHANCING ASSEMBLY EFFICIENCIES FOR MOTORSPORT
A leading advanced automotive technology firm sought a more efficient solution for the oil thermostat assembly in their latest advanced high-performance vehicle.
The existing fluid control plugs were proving problematic, primarily due to the installation complexity and concerns over long-term sealing reliability. These inefficiencies posed risks to both performance and production timelines.
The Challenge
The mechanical design team highlighted that the current plug fitting process was overly time-consuming and error-prone, requiring up to 30 minutes per unit. The company required a high- integrity sealing solution that would both streamline assembly and meet the exacting standards expected of top-tier motorsport engineering.
The Solution
A technical visit was arranged with the client’s engineering and assembly teams, during which Boneham & Turner presented the SFC Koenig sealing plug system, alongside complementary Boneham-engineered components.
The demonstration focused on:
• Rapid installation, dependant on application, Koenig Expanders can be set as quickly as 3 seconds
• Secure, permanent sealing under high-performance conditions, including pressure and vibration
• Integration suitability within complex gearbox and oil thermostat housing geometries
The time on the internal BOM (Bill of Materials) for the oil thermostat had 30mins to fit plugs. Now it is a 30 second job! The Assembly team
The Result
Following the demonstration, the motorsport company was convinced by the performance and design of the SFC Koenig plugs. As a result, the SFC Koenig sealing plugs were successfully integrated into the design of the cars oil thermostat and gearbox housing.
This project illustrates how advanced component engineering and collaborative supplier engagement can deliver transformative efficiencies in advanced propulsion manufacturing. Through precision design, faster assembly, and proven performance, the SFC Koenig solution, facilitated by Boneham & Turner, has become an integral part of this manufacturer's competitive edge.