Products and services > Assembly & Sub-Assembly of Components
At William Hughes, we specialise in manufacturing assembly and sub-assembly solutions, providing precision-engineered assemblies that ensure optimal performance and integrity. Our assembly services support a wide range of industries, including automotive, aerospace, medical, and high-tech engineering, offering tailored solutions to meet complex manufacturing demands.
By managing secondary processes such as mechanical sub-assembly, we help reduce lead times and improve production efficiency, allowing our customers to focus on their core manufacturing activities. Backed by advanced facilities and robust quality control, our assemblies consistently meet the highest standards of modern industry.
The Process of Assembly & Sub-Assembly In Precision Manufacturing
Our manufacturing assembly and sub-assembly processes begin with thoroughly researched project planning, including technical analysis and specification alignment. We then move to the assembly stage, utilising automated and manual techniques to guarantee accuracy within the agreed tolerance band. Each component undergoes stringent checks and balances throughout the process to maintain dimensional integrity and mechanical functionality.
Key stages in the process can include:
- Component Preparation: Cleaning, passivation, and quality inspection to ensure parts are contamination-free.
- Precision Assembly: Utilising advanced jigs and fixtures to maintain consistent positioning and alignment.
- Quality Assurance: Comprehensive testing and inspection to validate mechanical integrity and performance.
- Packaging and Labelling: Ensuring components are prepared for seamless integration into customer production lines.
We are able to simplify inventory and streamline manufacturing processes by supplying assemblies of metal components, for example welded metal parts with threaded inserts, chamfering, nibbing and injection overmoulding. This provides significant savings in assembly costs through simplification of the supply chain and a reduced number of in-house operations.
Types of Assembly & Sub-Assembly
We are able to offer a range of assembly and sub-assembly solutions, each tailored to specific applications and industries.
Approvals Include:
Our assembly and sub-assembly processes are fully compliant with:
- ISO 9001: Quality Management Systems
- IATF 16949: Automotive Quality Management
- ISO 14001: Environmental Management
Assembly Facilities
Our purpose-built assembly facilities are equipped with cutting-edge technology to accommodate complex assembly tasks with expert precision. We maintain clean and controlled environments to reduce contamination risks, essential for applications in the medical and high-tech sectors.
Our equipment portfolio includes:
- Automated Assembly Lines: Reducing manual intervention and enhancing throughput.
- Precision Jigs and Fixtures: Maintaining geometric accuracy across batches.
- Electro-Mechanical Integration Stations: Combining mechanical and electronic components seamlessly.
With dedicated spaces in all our factories for sub-assembly manufacturing, our facilities are designed to ensure smooth workflow and minimal lead times. We also implement stringent environmental controls to support sustainable manufacturing practices.
An Example of How Our Assembly Services Work with Automotive Seat Adjustment Sub-Assembly
An automotive OEM required high-precision wire form sub-assemblies for seat adjustment mechanisms. The challenge is to maintain dimensional accuracy while achieving consistent spring tension across multiple batches.
William Hughes would develop a custom mechanical sub-assembly process, utilising automated jigs to maintain alignment and robotic welding to ensure consistent joint integrity. Post-assembly, each unit would undergo rigorous tension and fatigue testing to validate performance under simulated real-world conditions.
As a result, we have the potential to reduce lead times by 40% and increase batch consistency to 99.8%.
Quality & Inspection Techniques
Ensuring the highest standards of quality, our assembly and sub-assembly processes incorporate advanced inspection methodologies, including:
- Dimensional Analysis: Using coordinate measuring machines (CMM) to verify geometric accuracy.
- Functional Testing: Validating mechanical performance under load and stress conditions.
- Visual Inspection: Detecting surface defects and assembly inconsistencies.
- Electrical Continuity Testing: For electro-mechanical assemblies, ensuring reliable connectivity.
Our commitment to quality is reinforced by continuous training of technicians and the use of digital tracking systems to monitor performance data and identify improvement opportunities.