Automotive EV Motor Housing — Production Scale-Up
Scaled from prototype (10 pcs) to production (5,000 pcs/month) for EV motor end housings with ±0.02mm tolerances.
The Challenge
After successful 10-piece prototypes, the customer needed to ramp to 5,000 units per month for a new EV platform launch. Critical bearing bores required ±0.02mm tolerance with 100% inspection. Any supply disruption would halt their assembly line.
Our Approach
- 01
Designed a dedicated production cell with twin-spindle VMC and automated in-process probing for bore diameter control.
- 02
Implemented SPC on bore diameter and concentricity — Cpk > 1.67 before SOP approval.
- 03
Developed a JIT kanban replenishment program with 2-week rolling forecast and safety stock buffer.
- 04
PPAP-equivalent documentation package including process FMEA, control plan, and capability study.
“Unique Prototype Technology took us from prototype to full production without a single line-down event. Their SPC data gave our quality team confidence to approve the supplier in record time.”
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