Case Study: Transforming Supply Chain Reliability for an International Machine Tool Builder

Transforming Supply Chain Reliability for an International Machine Tool Builder

Client Overview

Our client, a renowned international machine tool building, faced significant challenges in finding reliable suppliers to machine parts from iron castings. These components are critical to their intensive machine-building schedules, where delays and quality issues can disrupt production timelines.

Project Overview

The client sought a partner capable of delivering high-quality machined parts from iron castings while adhering to strict deadlines and budget contraints. Their previous supplier struggled with the technical complexities of machining castings, leading to spiralling costs and missed deadlines.

Challenges

Machining Complexity:
- Iron castings are notoriously challenging to machine, requiring expertise, traditional techniques, and meticulous attention to detail.
- Many subcontract machinists shy away from such work,
Spiralling Costs and Missed Deadlines:
- Unfamiliarity with large casting machining resulted in inefficiencies, cost overruns, and delivery delays.
Supply Chain Management:
- Ensuring proper treatment between machining operations added another layer of complexity to the production process.

Solution

Engineering and Machinability Consultancy
We began with a free Engineering and Machinability Consultancy session, during which we:
- Identified the root causes of inconsistencies in machining castings.
- Educated the client on the unique challenges of working with iron castings.
- Collaboratively developed a realistic production plan with clear expectations and accurate cost estimates.
Innovative Machining Approach
- Employed a combination of CNC and manual machining methods to maximise efficiency while maintaining the high precision required for castings.
- Designed a streamlined production line to handle the unique demands of machining large iron castings.
Supply Chain Management
- Managed the treatment processes between machining stages to ensure quality and compliance.
Partnership-Driven Development
- Maintained an open dialogue with the client to ensure deadlines were met, even under tight schedules.
- Suggested and oversaw a transition to the next-generation machine parts, replacing castings with solid material where feasible. This shift improved production predictability, reduced costs, and increased reliability.

Execution

Phase 1: Consultancy and initial production planning.
Phase 2: Established machining workflows and supply chain protocols.
Phase 3: Meeting deadlines for existing parts while planning the transition to solid material components.
Phase 4: Supporting the client through the redesign and implementation of new-generation parts.

Results

Improved Reliability: Delivered machined parts on time and within budget, ensuring uninterrupted machine-building schedules.
Cost Savings: Transitioning certain components from castings to solid materials reduced production costs significantly.
Enhanced Partnership: Built a collaborative relationship with the client, establishing Markyate Precision Machining as a trusted partner rather than just a supplier.

Conclusion

This project highlights our unique approach to subcontract machining: combining technical expertise, open communication, and strategic foresight to exceed client expectations. At Markyate Precision Machining, we don’t just deliver components; we build lasting partnerships that drive success.

Case Study.