Accuracy in automotive parts shipping and manufacturing is critical – even a few microns in measurement can affect vehicle performance and safety. But keeping those tolerances intact and unstressed while shipping the parts internationally becomes a challenge.
The automotive parts supply chain is a large and complicated one. From the moment the parts are left the original equipment manufacturer (OEM) until they are received at the service center, there are many hand-offs.
In this span of time there are dozens of breakdowns that can happen, which is why a comprehensive cross-border automotive logistics network is behind every successful automotive repair.
Understanding the Importance of Tight Tolerances
An engineering tolerance is the acceptable range of variation for a manufactured part’s physical dimensions or properties. There will always be slight differences due to machining capability and, even with the latest technology, perfection will never be attainable.
However, it is imperative to get as close to it as is possible, especially if you are to ensure the component will function as designed when the manufacturer assembles the parts.
For example, controlling the piston-to-wall clearance — the tiniest distance between the piston in the engine and cylinder wall— requires precise tolerancing. The clearance must be large enough to allows proper lubrication as well as permit for the expansion of the component when the engine reaches operating temperatures.
If the clearance is too large, the compression is decreased, the piston will impact the wall causing oil consumption, and diminished durability. On the other hand, if the clearance is too small, it will produce friction causing excessive heat to be generated; either way the components experiences excess wear, increasing the risk of catastrophic engine failure.
Most automotive issue stem from tolerancing failures. One example is the A/C compressor’s clutch plate, the part that engages the compressor when the A/C is turned on, is too close to the pulley when disengaged.
It drags, it wears excessively and will eventually make metal shavings that will clog the system and cause it to lose refrigerant. It engages properly and works less efficiency, thus you lose A/C.
Another example is the braking system. When stepped upon, brake pads squeeze the rotors to produce friction to slowdown or stopped the vehicle. They rely on tight tolerances to apply pressure evenly.
If any of the dimensions are off by even the slightest bit, they shake and squeal when being applied. As time goes on, if the wear is uneven, it just gets worse and brake performance declines.
The Importance of Automotive Part Precision to Drivers
OEM parts have tighter tolerances than aftermarket parts because of strict testing and quality controls. Even if you can see that the parts look the same, those slight differences are what can be the difference between a broken car or a working car. That is why when repairs are aftermarket, sometimes warranties are voided.
Today’s OEMs are producing vehicles with better tolerances for engine components, but they are also being developed under stringent government safety regulations with advanced manufacturing techniques. Since there is high quality material and manufacturing but potential for low quality parts to end up with the customer, it stands to reason then, that the quality of a part may be compromised before it even gets to the service center customer.
During shipment and handling, it is easy to miss precision tolerances while in transit. For example, if a compressor was improperly packed for shipment, it may shift in the delivery vehicle, and if that vehicle runs over a pothole, it may cause a minor scratch or even dent (even if this damage is hardly noticeable). Those minor damages can cause issues in how the vehicle operates, which is why a consumer driver would care about how a replacement part is shipped from a company.
The cost of replacement parts can add up quickly, with as much as $400 for brake pads, $500 for rotors and thus nearly $1000 for a simple repair. When a person spends this amount of money on a service, the expectation is excellence and the only way to guarantee excellence is to follow through with an automotive parts supply chain.
The Cross-Border Automotive Logistics Process
The integrity of automotive service repairs is a direct reflection of the efficacy of cross-border automotive logistics.
Typically, automotive spare parts entering the United States – Canadian border begin from an industry OEM factory, potentially moving through a series of nationwide suppliers and distributors, including customs inspections, ultimately reaching the dealership or service center where it’s being repaired and the certified mechanic will eventually install it.
Canada is the largest export market for America. Although Canada produces only 14 vehicle models, it consumes 325 vehicle models, many of which are made in the US.
North American automotive parts and pieces are produced in such a highly integrated supply chain that they cross the Canadian and Mexican borders upwards of eight times prior to assembly at the final location. For final vehicle assembly, the US is responsible for about half of what is needed for assembly.
No matter if professionals are dealing with a quote for a compressor replacement for a bus, or a new piston for a motorcycle, transporting automotive parts across the US-Canadian border entails a rigorous set of regulations.
The documentation consists of a minimum amount of documentation, and even the most simple traverse little, I mean very very little, forgets about stuff such as; industry equivalent for an importers identification number, a certificate of origin,
Logistics professionals transport goods in the supply chain with consideration for vibration, shock, temperature, compression, and humidity in their attempt to properly pack or have the shipment packed, to reduce the likelihood that the shipment would sustain damages during transit.
Logistics professionals play a role in the packaging of automotive parts that range in different degrees of size and packaging or materials. Handling parts that may be fragile, or awkwardly shaped, or say, large and bulky, is extremly physically challenging.
An integrated, systematic, and seamless cross-border network means minimal handling, and thus minimal possibility of damage or impaired shipments for subsequent handling. Thus the consumer is not worrying about epistemology of microscopic damage affecting performance or safety.
Maintaining Integrity With Environmental Control
Automotive materials are susceptible to temperature fluctuation in a variety of ways. Because they are all conductive metals, their malleability, length, volume and surface area have the possibility of increasing during thermal expansion.
In the simplest of terms, metals expand and contract as the engine heats and cools. OEMs have to allow for these changes to obtain their tolerances.
In the automotive industry, stocks of precision parts ship quickly. Nevertheless, there are still instances where deliveries can take days or weeks. Full palettes sit without airflow and temperature control.
It can get freezing cold or it can get to sweltering warm temperatures. Items could end up warping. These temperature fluctuations can result in stronger adverse effects during certain months of the year, climates and weather events.
Prolonged exposure to extreme temperatures also impacts rubber and plastic parts, such as gaskets, o-rings and seals. If it gets too cold, they will harden, become brittle or crack. If they get too hot, they will stretch beyond their functional ability or in extreme conditions, melt.
Take for example, heat resistant O-rings made of polyacrylate elastomer. These heat resistant O-rings boast this capability under the conditions of negative 68 degrees Fahrenheit to around 347 degrees Fahrenheit. They may however expand when heated which can lead to deformation. If the O-rings lose their ability to stretch, they will lose their ability to seal.
There are somewhat specialized methods of shipping with temperature control. These are typically active temperature protection solutions such as cooling systems. This shipping opportunity is most often taken advantage of when the latest cellular technology is used.
Many commercial delivery vehicles now include sensors in the back that are internet enabled and will monitor environmental conditions. If the temperature exceeds or falls short of preset threshold, an alert will notify the driver or an automated management system.
Vibration and Impact Protection for Automotive Components
Vibration and impact are problematic because they can cause damage to mechanical and electronic components that’s typically undetectable. First vibration and impact can cause mechanical damage by damaging the finish on the machined surfaces and causing scratches.
Further, vibration and impact can loosen screws and bearings and cause assembled systems to shake or even come apart. Also impact can cause microscopic fractures in cast pieces.
Here are some common automotive products that are typically sensitive to vibration.
- Engine control modules: This system contains electronic items like capacitors, wires, and microprocessors that will loosen if substantially jostled.
- Calibrated automotive components: Some manufacturers test and calibrate components that operate at tight tolerances. Vibration may throw them off and impact performance while in use.
- Precision machined automotive components: OEMs typically manufacture to specifications which means they have to be as close to perfect as possible. If vibration causes damage, it eliminates all of their hard work.
Logistics professionals can use the custom damping of packaging material or strategic pallet orientation in packaging to protect automotive precision machined parts while in transport.
They may even pay attention to the selected cross-border route and avoid the bumpiest conditions and use specific modes of transport selectively. They intentionally invest in technology that aides their monitoring so that they can adjust appropriately.
Supply Chains of Small Businesses’ Automotive Parts
Small businesses dealing with the shipment of automotive precision parts face several barriers, including lower shipping volumes, budget size and their lack of logistics expertise. These challenges limit their ability to utilize the newest and best methods for maintaining tolerances throughout the cross-border supply chain.
Independent repair shops and small suppliers will still have a number of options:
- Consolidation service: Consolidation services increase efficiency by combining multiple smaller shipments into one larger shipment, to reduce cost and improve delivery timelines.
- Cost effective packaging: Precision protection does not need to be priced prohibitively. Using lighter materials and better stack ability can minimize shipping costs.
- Partner selection: Specialized handling with consideration of time and performance is key to an effective cross-border automotive logistics process.
Pre-packaged programs specifically developed for small-volume automotive product shippers will be specific and useful compared to the generalized, one-size-fits-all programs on offer now.
This means owners will be able to improve their customs treatment, improve their documentation and improve their on-time rate without compromising the quality of their product by unintentionally altering tolerances.
Choosing the Right Logistics Partner for Automotive Parts
The right logistics partner can level the playing field for smaller operations in this business. If deliveries are made on time to a customer, the business can maintain customer satisfaction with the possibility of additional business.
A reliable logistics partner also helps those businesses improve overall bay scheduling so that technicians are serviced promptly to minimize idle time, and maximize productivity.
Purolator International is one very good example of a logistics company with several industry-specific success stories. As an expedited services solution to U.S. businesses that transport goods to, from and within Canada, Purolator provides service within a one to seven days delivery window depending on services, but also guaranteed.
The travel time to source replacement parts for motor coach distributors is significant, as there are no spare parts serviceability distributors in the country. Deliveries received with a tolerance — out of tolerance — are inacceptable. In this case the manufacturer to the motor coach trucks was offering same-day shipping with a money back guarantee so delays could not be tolerated.
Unless there were certain exceptions, Purolator’s services were faster and less cost than the alternative locations and service timelines. For instance, Purolator has guaranteed delivery to Canada in less than two days; they use the air freighter to expedite freight shipping for other shipments for about 10%. The manufacturer was so impressed, they renewed their annual contract.
The most proficient logistics providers, possess extensive industry experience in addition to cross border automobile logistics, specialized handling materials and tools as well as having strong quality management systems. They have deep knowledge and resources, which can benefit not just documentation and documentation management, but improve how shipments are tracked.
Ensuring Automotive Precision During Parts Shipping
Prioritizing automotive precision parts while shipping will keep parts intact and functional and ensure lasting quality performance. Shipping and handling are a huge component for preserving tight tolerances, and consumers should be serious about their search for a logistics partner.
In this market segment, it is important to find one that has cross-border experience in shipping automotive component replacement products.
Consumers will return to dealerships and independent repair shops offering high quality products because of the peace of mind they receive. Even when a consumer does not know the hidden story of precision maintenance behind vehicle parts, they want to believe in the mechanics.
As a result, consistency and control means repairs last longer and give the consumer the performance they have come to expect.