Revolutionizing Automotive Casting Efficiency

Client : A leading automotive parts supplier in the USA

Project : Optimizing casting processes for automotive assembly parts

Challenge :

The client faced increasing demand from automotive manufacturers, necessitating a reduction in turnaround time (TAT) for casting processes. The traditional methods were too slow to meet just-in-time delivery requirements, leading to potential delays and lost business opportunities. Additionally, maintaining high precision and minimizing defects in cast parts such as engine blocks and transmission housings was crucial for ensuring performance and reliability.

Key challenges included :

• Slow Turnaround Time: Traditional casting methods caused delays in production.

• Dimensional Accuracy: Achieving tight tolerances (within ±0.1 mm) was essential.

• Porosity Issues: Porosity in cast parts compromised their strength and durability.

 

Solution by HanaV Manufacturing :

HanaV Manufacturing implemented cutting-edge solutions to address these challenges, focusing on rapid casting techniques and automation.

1. Vacuum-Assisted High-Pressure Die Casting :This advanced method combines vacuum technology with high-pressure die casting to enhance the casting process :

• Vacuum Assistance : Eliminates air and gas pockets, reducing porosity and improving the mechanical properties of cast parts.

• High-Pressure Injection: Ensures molten metal fills intricate geometries with precision, achieving exceptional dimensional accuracy.

2. Automated Mold-Making with CAD/CAM Integration
To streamline mold design and production, automated mold-making processes were introduced using advanced CAD/CAM software:

• Efficient Mold Design: The integration of CAD/CAM enabled precise and consistent mold designs, reducing production time and ensuring high quality.

Technical Achievements :

• Turnaround Time Reduction : TAT reduced from 10 days to just 4 days.

• Dimensional Precision : Tolerances improved to ±0.1 mm.

• Efficiency Gains : Overall process efficiency increased by 35%.

• Market Share Growth : Enabled quicker response to market demands, increasing market share by 15%.

Implementation Steps:

Vacuum-Assisted High-Pressure Die Casting:

• Utilized vacuum technology to eliminate porosity and improve part density.

• Rapid injection of molten metal ensured precise filling and reduced defects.

Automated Mold-Making with CAD/CAM Integration :

• Advanced software streamlined mold design and production.

• Faster mold production cycles reduced lead times significantly.

Business Impact :

The adoption of advanced casting technologies delivered significant benefits for the automotive parts supplier:

• Faster Turnaround Time: Reduced from 10 days to 4 days, ensuring timely delivery to clients.

• Enhanced Casting Quality: Improved precision and reduced porosity resulted in high-quality cast parts, minimizing rework and machining needs.

• Increased Efficiency: A 35% boost in process efficiency led to cost savings and greater production capacity.

• Competitive Edge: The ability to meet just-in-time delivery requirements improved the supplier’s reputation, driving a 15% growth in market share.