The Challenge
An electric vehicle OEM needed high-volume aluminum connector blocks at an aggressive per-piece cost target. Their previous supplier could not hold the position tolerance on the bolt pattern across volume.
Our Approach
Our team designed a 6-station tombstone fixture that ran 6 parts per cycle. We implemented SPC monitoring on the critical bolt-circle dimensions and used in-process probing every 50 parts to detect tool wear before it affected tolerance.
The Results
- Cost target met: $2.87 per piece at 10,000 units
- Position tolerance Cpk: 1.92 (industry-leading)
- Delivered in 6 weekly batches via DDP air freight
- Zero rejected parts at customer incoming inspection