Challenge:

The key to building a machine to meet the client’s demands depended on engineering expertise, extreme attention to detail and a constant line of communication between Alaark and the client. Not only were they building a machine that verified the machining process as well as inserted dowels into holes at the proper depth and force, Alaark had to allow for two different casing types to be run through this machine. 

Most important in the process was for the engineering design to achieve strict, tight tolerances while allowing for the use of two casting types. 

Solution:

Alaark engineers requested prints for both casing types and went to work. They studied and deconstructed the process that went into machining the two different castings and first drafted an inspection process that checked for flatness, through-holes, and the presence of threads in designated holes.

Alaark engineers then met with the client to review their solution, as well as to hear their perspective to make sure they’d accounted for all of the clients needs for the project. The engineers then returned to Alaark to develop a more concrete solution, after which they would once again review with the client.

Once the design specs had been confirmed and approved, Alaark began detailing prints and ordering materials to the client’s specifications. Alaark then created and assembled the machine to complete the necessary tests and actions on the automotive castings. Once the machine was built, Alaark performed a series of tests and troubleshooting actions to make sure the machine was functioning properly.

Essentially, Alaark requested a master reject casting and a master approved casting from the client which would allow Alaark to run the parts through the machine multiple times. In order to pass, the machine would have to label the master reject as having “failed”, and the master casting as having “passed.” Through a series of calibrations, Alaark provided the client with a finished product that performed under the exact specifications outlined.

The client was thrilled with the project, and ended up calling on Alaark to fashion camera systems to the machine so they could employ more detailed tracking methods with the castings in the form of scanned barcodes.