[Automotive] 50% shorter setup time with stable micron-level perpendicularity | Case Studies

Client Profile

A major automotive parts manufacturer in central Japan. Focused on precision machining of engine parts, shipping tens of thousands of parts per month.

Challenges Before Introduction

Heat from electromagnetic chucks caused workpieces to expand slightly during machining, deforming after cooling.
Custom fixtures for complex shapes were heavy, and changeovers took more than an hour.
Re-measurement and rework to guarantee accuracy had become routine, hurting yield.

Proposal and Technical Approach

We proposed a dedicated pallet system based on Sun Ai's permanent-magnet chucks, which achieve zero thermal displacement.

No self-heating: A structure that generates no electrical heat keeps workpiece dimensions constant even during long continuous machining.
One-touch clamping: A tool-free clamping mechanism simplifies mounting and removal of heavy fixtures.
High-rigidity base: A machined base plate absorbs micro-vibrations during machining.

● Results After Introduction

Within three months of introduction, the following results were measured.

Setup time: 65 min to 20 min (about 70% reduction)
Defect rate: 2.5% to below 0.1% (dimension errors from thermal displacement eliminated)
Monthly utilization: With rework time at zero, effective production capacity rose by 25%.

Customer Comments

"What convinced us was that they went beyond simply supplying a product - they fine-tuned the clamping force to match the characteristics of our machines. Now the shop floor says they never want to use any chuck other than Sun Ai's." (Manufacturing Manager, Mr. K)

Future Outlook

Currently introduced on only some lines, with rollout to all lines planned from next fiscal year. Integration with automated transfer robots is also being developed jointly with Sun Ai.