Introduction
- AMSOL Industries Pvt Ltd, a leading manufacturer of engineering components based in Rajkot, India, specializes in pump, valve, and automotive parts that meet international standards.The company is recognized for its innovative problem-solving and efficiency-driven culture within the manufacturing sector.
Challenges
- An automotive client shared a component drawing and requested production using the investment casting process. Upon initial review, AMSOLʼs engineering team found the process feasible but identified potential areas for improvement in terms of cost and mechanical properties. Investment casting, while efficient for producing complex shapes, hosts limitations in material strength and process lead time for high-stress automotive applications.
Solutions
AMSOLʼs technical evaluation involved :
- Reviewing dimensional, mechanical, and functional requirements.
- Conducting a comparative feasibility analysis for investment casting versus forging.
- Collaborating with the client to discuss alternative manufacturing routes.
AMSOL proposed converting the component from investment casting to forging. Key reasons for this shift :
- Forging offers superior grain structure and mechanical strength, critical for automotive stress environments.
- Faster process cycle times and improved output rates.
- Potential for significant cost reduction due to simplified production and lower material wastage.
AMSOL aligned the final part design and process with forging capabilities and undertook test trials to validate performance before serial production.
Results
The conversion to forging delivered :
- Cost Reduction : Approximately 35-40% savings over the investment casting method, benefiting both AMSOL and the customerʼs supply chain economics.
- Shorter Manufacturing Cycles : Forging allowed for increased throughput and reduced lead times, improving order responsiveness for the automotive client.
- Improved Mechanical Strength : Forged components showed better grain alignment and fatigue resistance, resulting in higher reliability under operational stresses—essential for automotive use.
- Quality Consistency : The forging process eliminated variability and porosity seen in some cast parts, further enhancing component performance and lifecycle.
Conclusion & Takeaways
AMSOL Industriesʼ proactive approach and expertise enabled a successful conversion from casting to forging, delivering measurable financial and technical advantages to the client. The case demonstrates AMSOLʼs :
- Commitment to value engineering and cost reduction.
- Skill in feasibility analysis and advanced manufacturing strategy.
- Ability to partner with automotive clients for superior product outcomes.
AMSOLʼs intervention not only met the clientʼs requirements but also set a benchmark for manufacturing excellence in Indiaʼs automotive supply sector.