Case Studies

Process Change Cures Burrs

An engineering company was unable to eliminate burrs in the manufacture of a precision cylinder component.  The issue impacted quality, decreased efficiency and increased handling, which resulted in an increase in cost.

After analyzing the problem, KCS developed a new machining process for the hole-drilling operation.  Using a 5-axis machine, KCS developed a specialized routine that created a difficult-to-machine chamfer on the underside of the component.

The KCS solution completely eliminated burrs and elevated both quality and efficiency while reducing cost.

High-End Component Process Enhancement & Cost Reduction

A specialty manufacturer of high-performance race motors and components needed to find a machining solution that could maintain quality standards and lessen production costs in the manufacture of a complex, low-volume / high-end engine component.  The component required multiple machining and finishing operations and processes.  It also had to hold or exceed critical production tolerances much tighter than the norm.

KCS engineered and fabricated specialized fixtures that brought more efficiency and precision to the complicated, multi-process manufacturing evolution. This included a reinvention of the machining sequence in such a way that handling and machine time were lessened.

Designing, testing and machining was done in-house at KCS.  The component – a manifold for a 4,400 HP twin-turbo race hemi motor — was machined from a 750 pound block of aluminum and features removable 4” runners.  KCS machined the compound curves for the throttle bodies on a 3-axis machine.  KCS exceeded all customer expectations, significantly cutting both cost and scrap while actually reducing production tolerances.

A Commoditized Engine Component Solution

A major automotive aftermarket manufacturer was looking for machining options to help maintain or raise quality while reducing production costs for a mature, commodity component.

The KCS design team studied the challenge and analyzed potential outcomes, then developed three options comprised of variations in material used, machining operations required and handling.  The KCS analysis captured the plusses, minuses and cost involved for each option and helped the customer arrive at a solution that reduced handling and scrap, used better material that would increase lifecycle while reducing potential warranty issues, reduced cost and shifted to a leaner, JIT process.