Effective Protection Solution for Automotive Cooling Lines
Dust Control
Precise Fit
Reliable Supply
Securing Cooling Systems: 1 Million Caps in 2 Months
In automotive cooling line systems, even minor contamination can lead to quality issues and production disruptions.
When a Tier 1 supplier faced an urgent challenge related to contamination inside cooling pipes, DBI provided a reliable protection solution within a short timeframe. More than one million caps were delivered to secure both ends of the cooling lines and ensure clean handling throughout logistics and assembly.
About Our Partner
A leading supplier to the automotive industry, serving applications that require high standards of quality, cleanliness, and product integrity. The company operates under stringent manufacturing and supply chain requirements.
Challenges
Protection of both ends of the lines
Each component needed secure closure on both inlet and outlet to prevent contamination during handling and transport.
High-volume demand under time pressure
The total demand exceeded one million units, with delivery required within a very short timeframe of 3-4 weeks, demanding a scalable and reliable supply.
Multiple sizes and accurate fit
The solution had to cover four VDA-based dimensions, ensuring precise fit across all cooling line variants.
Our Solutions
DBI delivered a robust and scalable solution based on standardized DT range VDA plugs for cooling line applications.
Production, planning and logistics teams worked in close coordination across locations to ensure stable and continuous supply.
Effective protection of cooling line interiors
Proven fit based on VDA system standards
Reliable delivery performance
High-volume supply
Value-Added Services
Fast process and delivery execution
Short response time from request to production and shipment.
Flexible capacity management
Adjustment of production schedules to handle peak demand.
Cross-department teamwork
Strong cooperation between planning, production and warehouse teams ensured smooth execution.
Operational support under pressure
Ability to maintain delivery flow despite high demand and operational challenges.
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Results & Impact
1 million VDA plugs delivered!
DT range: NW6 / NW8 / NW16 / NW20
Planned as annual volume, completed in just 2 months
Lead time: 7–8 weeks
Contamination risk eliminated
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