A rising German electric vehicle brand focused on lightweight design is seeking reliable precision component suppliers for its next-generation electric drive system.
High Precision Requirements: The motor housing (material: AlSi7Mg) needs to ensure bearing concentricity ≤0.015mm and sealing surface flatness ≤0.02mm, directly impacting motor efficiency and noise.
The initial order is for 500 units, requiring absolutely consistent quality for each piece, with no batch variations.
The client's new vehicle project has set milestones, leaving only a 5-week window for component production.
Process Analysis and Optimization (demo text)
Using our five-axis machining center, multiple angled holes and curved surfaces that traditionally require 3-4 clamping operations can be completed in a single clamping operation, eliminating repetitive positioning errors.
Engineers designed a modular hydraulic fixture for this housing. Operators can easily switch workpieces with simple actions, reducing single-piece clamping time from 5 minutes to 45 seconds, laying the foundation for subsequent mass production.
After programming and fixture debugging, the first article is produced and immediately inspected for full dimensions using a coordinate measuring machine (CMM). The data report is submitted to the customer for confirmation within 4 hours.
During mass production, critical dimensions are sampled and inspected every 50 pieces processed, and the data is recorded in SPC (Statistical Process Control) charts to monitor process stability in real time.
Processed parts undergo a fully automated cleaning line to ensure no aluminum shavings or coolant residue remains, and are finally vacuum-packed in a temperature- and humidity-controlled workshop.
The final delivery yield reached 99.8%, and all critical dimension CPK values were greater than 1.67, far exceeding customer expectations.
Production efficiency was improved by 40% compared to the customer's previous supplier, helping the customer reduce the overall procurement cost per unit.
We completed delivery two weeks ahead of schedule, allowing valuable time for the customer's complete machine assembly. Based on this successful collaboration, we have been upgraded to a strategic supplier of chassis and electric drive structural components for this customer in Asia and received their "Innovation Partner of the Year" award.
