1. New Product Type and Design Complexity

Challenge:
Although the supplier had experience with general metal boxes, the Vietnam ammunition box PA171 introduced a completely new structure and design. Both the jigs and molds had to be developed from scratch.

Solution:
VNO engineers guided the factory through the tooling design phase, ensuring that bending, rolling, and welding jigs supported accurate geometry. The new system shortened setup time and improved repeatability.

2. Equipment and Capacity Limitations

Challenge:
The product’s dimensions exceeded the capacity of existing welding machines. In addition, the factory had never applied copper conductive coating before.

Solution:
VNO and the supplier re-engineered the production line. They customized welding tables and extended the work area to accommodate the longer product size. For the coating process, VNO introduced new surface treatment methods and verified results through joint quality testing.

3. Gas Leak and Pressure Testing Requirements

Challenge:
Maintaining airtight welding across long seams was critical to prevent gas leakage during testing.

Solution:
VNO trained the supplier’s quality team to perform leak detection using air pressure and immersion methods. All Vietnam ammo boxes were tested at both factory level and customer-specified conditions to ensure full compliance.

4. Process Optimization for Cost and Efficiency

Challenge:
To compete with Chinese manufacturers, the supplier needed to increase production efficiency while maintaining consistent quality.

Solution:
VNO worked closely with the supplier to standardize the production flow, minimize rework, and shorten lead times. By improving welding fixture setup and introducing lean manufacturing practices, productivity increased by 15%, and defect rates dropped significantly.