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Synerject Manufacturing Dave Kilgore

Synerject Manufacturing Dave Kilgore. Synerject Manufacturing Locations. Delavan Wisconsin USA. Changchun China. Newport News Virginia USA. Page 2. Automated Mechanical. Manual Mechanical. Electronics. Manufacturing Assembly Lines. Assembly and Test Equipment

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Synerject Manufacturing Dave Kilgore

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  1. Synerject Manufacturing Dave Kilgore

  2. Synerject Manufacturing Locations Delavan Wisconsin USA Changchun China Newport News Virginia USA Page 2

  3. Automated Mechanical Manual Mechanical Electronics Manufacturing Assembly Lines • Assembly and Test Equipment • Mechanical, Electronics, and Mechatronics Assembly and Test • Fully automated, semi-automated and manual assembly lines • Flexibility designed into processes and tooling • Quick changeovers and minimal capital expense • 100% performance testing when required Mechatronics

  4. Mechanical Process Specialties • Laser welding • Hermetic and structural welds • Leak testing • Pressure Decay • HMS (Helium Mass Spectrometer) • Bubble Leak Testing • Precision assembly • Smart Press Technologies • Customized assembly fixtures • Insert Plastic Molding as part of the assembly process • Precision part washing using aqueous cleaners Laser Welding Difficult Steels Helium Mass Spectrometer Leak Testing of Critical Components Insert Plastic Molding

  5. Electronics Process Specialties • Automated Dual Sided SMT assembly • “No Clean” Solder Process • Point to Point Selective Soldering Systems • 12 layer/2 oz copper PWB capability • High Reliability Electronics Manufacturing – IPC Class 3 • In Circuit Test Systems • Customized Functional Test Development • HALT/HASS capabilities 4 SMT LINES AUTOMATED SOLDERING SYSTEMS FUNCTIONAL TEST 3 HALT/HASS CHAMBERS

  6. Manufacturing and Quality Capabilities • All manufactured products comply with the Synerject IS0 9001:2008 Quality System • Certified Six Sigma Black Belts on staff • Quality Tools used in the manufacturing process • SPC, Root Cause Analysis, etc. • Lean Manufacturing and Lean Office Programs in all locations • Process and tooling development • Manufacturing control plans focused on zero defects • Precision component assembly and test • Component tolerances to +/- 3 micron • Assembly matching to +/- 1 micron • Assembly tolerances to +/- 10 microns

  7. Electronic Control Units and Modules Throttle Body and Electronic Control Unit Module Electronic Control Units

  8. Fuel Rail Assemblies Port Injection Single Cylinder Rail (motorcycle engine) Inline 4 Stroke Port Injection Fuel Rail Assembly (inboard marine engine) 2 Stroke Direct Injection Fuel Rail Assembly (outboard marine engine) 4 Stroke Port Injection Fuel Rail Assembly (V-Twin motorcycle engine)

  9. Fuel Delivery Modules Metal Flange Fuel Delivery Module with Thermistor Fuel Level Switch (typical motorcycle, ATV application) Conductive plastics Return or Returnless With/without System Fuel Filter With/without Pressure Regulator Fuel Delivery Module with Automotive Level Sender (typical motorcycle, ATV application) Fuel Delivery Module with Internal Jet Pump (Snowmobile Application)

  10. Fuel Hose Assemblies Fuel Hose Assemblies (all application types)

  11. Direct Injectors Direct Injectors (marine, motorcycle and ATV applications)

  12. Plastic Body, Tank Mounted (Snowmobile Applications) Aluminum Body, Flange Mounted (Outboard Marine Applications) Plastic Body, Tank Mounted, with Hoses and Harness (Outboard Marine Applications) Electric Oil Pumps

  13. Customized ETC Actuators ETC Actuators using automotive components customized packaging

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