The March 2011 earthquake in Japan forced many businesses to re-think their supply chain, including Honda Lock America. A wholly owned subsidiary of Honda Motor Company, Ltd, Honda Lock America manufactures safety/security devices for automotive, motorcycle and personal watercraft applications. At the time HLA didn’t intend to add any additional suppliers but due to disruptions in their supply chain from the 2011 earthquake, HLA wanted to explore options of sourcing emblems domestically.
GM Nameplate already produced various badges and other emblems for Honda. Through utilizing GMN’s patented Lensclad (thin dome process), the project was a perfect fit for GMN. The emblem is made from a thin layer of aluminum, printed with black, embossed with brass and then the thin dome Lensclad also creates a protective layer. Lastly, the part is blanked to size.
During the development of the part, many trips were made to HLA’s Georgia and Alabama facilities to observe the application process of the emblems. While visiting HLA’s facilities, GMN noticed they have a large scrap rate on the application of emblems to the plastic key fob.
GM Nameplatedevised a special process, resulting in a significant decrease in the scrap rate. By utilizing an existing transfer adhesive, which is used on automotive exterior badges, and combining with a unique application process, GMN was able to lower the total cost per part. In the end, GMN’s innovative approach to the creating the part resulted in an approximate 30% cost savings due to reduced scrap rate and currency valuations.