Challenge: Rapid development of 21 complex parts, in aluminium and steel, for a US$ 14 billion aerospace major.
Approach: Zenith executed this project by evolving an optimal manufacturing sequence best suited for the volumes; designing and manufacturing specialised fixtures; and selecting latest technology tools and engineering services (including PPAP & PFMEA). We had a SPOC work closely with the customer to ensure swift response and on-time completion of project.
Outcome: Based on our ability to sustain demanding quality standards and consistently supply on time (while also offering substantial cost savings), we helped our customer address his supply chain risk by ensuring uninterrupted production and delivery schedules.
Challenge: Development and production of a set of 9 machined rings in steel for a global locomotive manufacturer. These were the largest rings we had made so far, requiring extremely close tolerances and special painting.
Approach: Zenith located, tested and qualified a reliable local source for the material. We invested in a turning centre capable of machining 600 mm dia. with close tolerances. All work-holding fixtures were custom designed and manufactured exclusively for this project. We also established a local painting source to undertake special painting which required 2,500+ hours of testing.
Outcome: Successful execution of this project led to series production. Shortly after, the customer forwarded a high value inquiry for a similar machining requirement.
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.
Zenith Precision Private Limited
94, 7th Main, 3rd Phase,
Peenya Industrial Area
Bangalore 560 058, India