Case Study: Reducing Lead Time by 30% for a Complex Automotive Assembly
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- Source:ZetPart
In the highstakes world of automotive manufacturing, extended lead times for complex components can derail production schedules and inflate costs. A prominent automotive supplier faced this exact challenge with a critical, multipart aluminum housing assembly. The component required intricate milling, tight tolerance boring, and precise threading. Their existing supply chain, fragmented across multiple domestic shops, was causing a 12week lead time, creating a significant bottleneck. They approached our company, a specialized provider of onestop CNC machining and batch production services, seeking a solution.
Analysis and Strategic Overhaul
Our initial audit revealed the core issue: logistical delays and inconsistent quality checks between different machining stages. The part was being shipped between three separate facilities for milling, finishing, and quality control. Our strategy was to consolidate the entire manufacturing process under our onestop roof. We leveraged our inhouse capabilities, which include advanced 3, 4, and 5axis CNC mills, a dedicated quality lab with CMM, and a seasoned engineering team.
The key to success was Design for Manufacturability (DFM) analysis. Before production began, our engineers collaborated with the client to optimize the part design. We identified several noncritical features that could be simplified without compromising function, allowing for more efficient tool paths and reducing machining time by 15%. Furthermore, we standardized tooling and fixturing for the entire batch, minimizing machine setup changes between operations.
Implementation and Tangible Results
CNC machining
Production was executed on our highspeed 5axis machining centers, allowing us to complete complex geometries in a single setup. This eliminated the errors and time losses associated with refixturing. Our inhouse quality team conducted inspections at every critical stage, using CMM to verify tolerances, rather than waiting until the end of the process. This proactive approach caught potential deviations immediately, ensuring a firstpass yield of over 98%.
The results were transformative. By eliminating external logistics, optimizing the machining process, and integrating quality control, we slashed the total lead time from 12 weeks to just 8.5 weeks—a reduction of over 30%. The client not only met their urgent project deadline but also benefited from consistent, highquality parts and a simplified supply chain.
This case study underscores a critical advantage for global manufacturers: a centralized, expert partner for batch CNC machining is far more efficient than a disjointed network. We specialize in turning complex assemblies into streamlined, ontime deliveries, driving growth for our clients by ensuring their production lines never wait.