Challenge: Manufacture of a large set of complex brake parts for a US$ 1.2 billion global transportation major involving multiple operations, including deep-hole drilling, close tolerance holes, non-standard threads, and critical profiles.
Approach: As this was a high mix-low volume project, fixtures had to be designed and manufactured for multiple setups for each component. Special tooling and gauges were also developed. Machining was carried out on a combination of vertical machining centres, turning centres and horizontal machining centres.
Outcome: We were able to support the customer by establishing 30+ parts, over a period of three months, and begin serial production for this high-visibility, time-critical project.