Window Closing Effort
A high volume automobile had a problem with window closing effort. While the ideal value for window closing is 12.5 in-lbs, both right and left side windows were averaging around 20.0 in-lbs, which caused multi-million dollar warranty costs.
The window closing effort problem presented many interesting and serial problems. ASI Consulting Group recommended optimized tolerances of components around the door assembly and window regulator.
The team finished tolerance design in two weeks. As a result, tolerance of two components was adjusted and window efforts were reduced to approximately 13 in-lbs. There was a multi-million dollar reduction in warranty costs.