It was a Friday afternoon when the call came in. Before we knew it, we were headed out on an urgent mission across state lines. SMC responded urgently, because we knew we had to do what it took to salvage a CNC project.
We had quoted the project for large military vehicle parts a year earlier, only to learn that another CNC machining company was awarded the contract. Now, the CNC company was in financial distress, and the purchasing manager for the military vehicle parts called us in a panic.
“The CNC shop is going into receivership. They’re being shut down on Monday,” he said. “We need your help.”
So, a team from SMC hit the road Monday morning at 2:30 AM to review their fixtures and see if there was anything we could use to pick up where the other CNC company left off.
It wasn’t that simple…
The Part: Large, Complex, and Full of Surprises
At the center of the challenge was a massive cast component that stood nearly five feet tall — a critical-use part for the cooling system in a military vehicle. It wasn’t just the size that made it difficult. This part demanded multiple precision operations, each one pushing the limits of tolerance control. Flatness specs were especially tight, and because of the part’s size, geometry, and material composition, achieving them required both skill and adaptability.
Another challenge? The customer was already behind on production, and the fixtures and tooling from the failed CNC shop needed to be completely redesigned and rebuilt to meet specifications. Even if the other CNC shop kept going with their approach, they weren’t able to gain PPAP (Production Part Approval Process) acceptance after more than a year of submitting data. All parts were being shipped under a deviation, and their process was slow, affecting their ability to meet demand.
RELATED: Exploring CNC Machining of Tight Tolerance Production Parts
When the Unexpected Happens at the Foundry
Adding to the complexity, the original foundry supplier changed their business strategy and would no longer support the project. Stecker was tasked with finding a new foundry, which was no small feat given the part’s large size and tight tolerance requirements. Because of our strong partnership with Wisconsin Aluminum Foundry, we developed a tailored solution to meet needs of this project.
Changing foundries required all-new tooling, and despite best efforts, the initial castings no longer met flatness specs. The change in material behavior, especially the tendency for the part to “spring back” after the surface was machined, demanded a new approach.
Fixturing and measurement were a constant battle, one that required operators to monitor part movement closely with indicators and make real-time adjustments at each setup. Stecker’s team identified that adding a qualifying machining operation could potentially stabilize the part early in the process. While it added complexity, this adjustment proved essential to achieving a consistent, high-quality outcome.
More Steps. Added Fixtures. Better Outcome.
To meet the part’s flatness requirements and overcome the unpredictability of the castings, our team at Stecker made a bold decision: add a new roughing operation early in the process using a custom-built qualifying fixture. While this was a sizable investment on our end, we knew it was necessary.
Typically, adding machining steps increases lead time and complicates scheduling. But in this case, the additional operation actually improved efficiency. Before the change, the team struggled to get the part into a stable production cycle, handling pieces one at a time and constantly battling inconsistencies between operations. With the new approach, parts could be run more predictably across two machining centers, resulting in improved manufacturing consistency and reduced cycle times.
It was a counterintuitive move that proved critical. When combined with adding a second shift to catch up on the backlog left by the other machine shop, we met the customer’s deadline despite the project’s complexity.
“We added a second shift, not because we had to, but because we promised delivery on time. And we kept that promise.”
Smart Planning. Skilled People. Stronger Results.
Few shops are equipped to handle this kind of variability, especially at scale. But for Stecker, it was just another complex challenge worth solving. Through careful planning, seasoned operators, and real-time collaboration between engineering and production teams, Stecker developed a robust process. And going the extra mile with added fixtures and overtime helped bring the project across the finish line on time and on budget.
Ready to work with a CNC manufacturer that goes the extra mile and does what it takes to solve your toughest challenges? Contact our team to discuss your project.
