Tier-1 EV charging-port housings — 1.2M units/year
Cpk improved from 0.91 to 1.78; line-stops eliminated for 18 months running
Problem. Existing supplier could not hold ±0.05 mm flatness on a PA66-GF30 charging-port housing across a 16-cavity tool. Tier-1 risked line-stop penalties at the OEM.
Solution. Re-cut the tool with conformal cooling on the high-warp rib, switched to sequential-valve gating, and added in-line CMM with statistical-process-control feedback to the press controller.