Summer 2008, Aluminum cylinder head:

MCI machined prototype volumes of over 1,000 pieces of a new, complex cylinder head for an Automotive OEM.  Complexity on this cylinder head is defined by features such as double overhead cam, 4 valves per cylinder, compound angle lubrication holes, and true position call outs to projection points in the space, combined with extremely close tolerances (±.0003” in diameters, and as low as .0005” True Position).

MCI was awarded this job based on our quality reputation, communication, and response speed:

• Holding fixtures were designed and built in-house in 5 weeks.
• Special cutting tools and dedicated gages were designed and purchased during this timeframe, working with our select tooling suppliers.
• Two-stage leak test tooling was designed and built in-house, as well as assembly fixtures and cutting tools.
• Work performed on the cylinder head: Rough machining, 1st leak test, valve seats and guides assembly, finish machining, final assembly, 2nd leak test, packaging, with series of inspections in-process inspections between operations.
• Machined at an average rate of 40 cylinder heads per week, since Jan 2008.
• MCI met the program timing and cost targets using simultaneous engineering between MCI and the OEM engineers, while implementing ongoing engineering changes.
• Our cylinder heads exceeded performance specifications regarding combustion chamber leak rate.
• MCI also ran line try-out volumes of this cylinder head, working jointly with the OEM’s Advance Manufacturing Engineering group, presenting “lessons learned” during our prototype run and recommendations for improvements.  Performed operations at different level of completion, prior to production launch, in order to validate dedicated production equipment at OEM.

MCI saved the customer money by reducing program lead-time through:

• In-house design/build of test and assembly tooling
• In-house design/build holding fixtures
• Conducting simultaneous engineering activities that led to process engineering improvements