Precision Requirements
Pitch tolerance of ±0.05mm across the full 50,000-unit run.
Documentation
Full PPAP Level 4 submission including PFMEA and control plans.
AUTOMOTIVE CASE STUDY
Precision Automotive Timing Chain
Delivered 50,000 precision timing chains for a European Tier-1 automotive supplier in 6 weeks with 99.8% quality pass rate and full PPAP Level 4 documentation.
50,000Units Delivered
6Weeks Lead Time
99.8%Quality Pass Rate
18+Years manufacturing
0.8–18 mmCustom chain widths
30+Finishes available
100%Pre-shipment inspection
THE CHALLENGE BEGINS
Client Requirements
A European Tier-1 automotive supplier required a high-precision timing chain for a new engine platform.
ENGINEERING HURDLES
Technical Challenges
The project presented several engineering challenges.
Tight Pitch Tolerance
Maintaining ±0.05mm pitch tolerance required precision tooling.
Wear Resistance
Timing chain demanded high wear resistance under high-temperature operation.
PPAP Documentation
Full PPAP Level 4 required complete traceability.
ENGINEERING RESPONSE
Our Solution
We developed a complete engineering solution covering material, tooling, and process control.
01
Material Specification
Selected high-carbon C45 steel for optimal wear resistance.
02
Tooling Design
Precision progressive die tooling with in-die sensors.
03
Process Control
Real-time SPC monitoring with automated dimensional checks.
SAMPLING JOURNEY
Prototyping & Iterations
Three prototyping iterations refined the chain design.
Week 1-2
First Prototype
Initial sample on prototype tooling.
Week 3-4
Engineering Sample
Refined sample with updated tolerances.
Week 5-6
Golden Sample
Final approved sample on production tooling.
QUALITY ASSURANCE
Testing & Validation
Comprehensive testing validated the chain performance.
DELIVERY EXCELLENCE
Mass Production Results
Mass production delivered on schedule with consistent quality.
50,000
Units Delivered
Across 6 weeks
99.8%
Quality Pass Rate
First-pass yield
100%
On-Time Delivery
Met all milestones
Production Timeline
Quality Metrics
Pitch Tolerance±0.05mm
Breaking Force6.5 kN
Wear Depth< 0.1mm
CONTINUOUS IMPROVEMENT
Lessons Learned
Key takeaways that inform continuous improvement.
01
Early Tooling Investment
Precision tooling reduced pitch variance by 40%.
02
SPC Integration
Real-time SPC caught 95% of process drift.
03
Documentation First
Building PPAP documentation streamlined submission by 30%.