Why Did This Aerospace Supplier Choose Our Servo Press Technology?
Precision, traceability, and zero-defect manufacturing are non-negotiable in aerospace components production. This case study examines how a tier-1 aerospace supplier achieved unprecedented quality levels and regulatory compliance through advanced servo press technology.
Client Profile
Industry: Aerospace Components Manufacturing
Location: North America
Certifications: AS9100D, NADCAP, ISO 9001:2015
Specialization: Flight-critical structural components, engine parts, landing gear components
The client supplies major aerospace OEMs including Boeing, Airbus, and Lockheed Martin, where quality failures carry catastrophic consequences.
The Challenge
Quality Compliance Pressure
- Increasing OEM quality requirements exceeding current capabilities
- Manual documentation processes prone to errors
- Limited traceability for root cause analysis
- Audit findings requiring corrective actions
Technical Limitations
- Conventional hydraulic presses lacking process control precision
- Inability to monitor and record forming parameters in real-time
- Part-to-part variation exceeding tight aerospace tolerances
- Complex forming operations requiring multiple press stages
Business Impact
- Risk of losing contracts worth $12 million annually
- Extended lead times affecting customer relationships
- High inspection costs (35% of production labor)
- Limited ability to quote on new complex component programs
The Solution
We proposed a comprehensive solution addressing quality, traceability, and flexibility requirements:
Primary Equipment: LFP-SV500T Servo Press
- Capacity: 500 metric tons
- Control: Full servo drive with programmable slide motion
- Precision: ±0.01mm repeatability
- Monitoring: Integrated tonnage monitoring with 1000Hz sampling
Quality System Integration
- In-die sensors for process parameter monitoring
- 100% automated dimensional inspection
- Real-time SPC (Statistical Process Control)
- Complete electronic travelers with full traceability
Data Management Platform
- Press data integrated with MES (Manufacturing Execution System)
- Cloud-based data storage with 15-year retention
- Instant retrieval for customer audits and investigations
- Automated quality certificate generation
Implementation Approach
Validation Protocol
- IQ (Installation Qualification): Equipment verification against specifications
- OQ (Operational Qualification): Process parameter validation
- PQ (Performance Qualification): Production run validation with customer witness
- PPAP: Production Part Approval Process documentation
Timeline
- Month 1: Equipment manufacturing and factory acceptance test
- Month 2: Installation and integration
- Month 3: Validation and qualification runs
- Month 4: Customer PPAP approval and production release
Results Achieved
Quality Performance
| Metric | Before | After | Improvement |
|---|---|---|---|
| First Pass Yield | 94.2% | 99.7% | +5.5 points |
| CPK Value | 1.25 | 2.08 | +66% |
| Dimensional Variation | ±0.08mm | ±0.02mm | -75% |
| Customer Rejects | 3.2 PPM | 0 PPM | 100% elimination |
Traceability & Compliance
- 100% electronic records for every part produced
- Complete parameter history (tonnage, position, speed, time)
- Audit preparation time reduced from 3 days to 2 hours
- Zero non-conformances in AS9100 surveillance audit
Operational Efficiency
| Metric | Before | After | Improvement |
|---|---|---|---|
| Inspection Labor | 35% of production | 8% of production | -77% |
| Setup Time | 90 minutes | 22 minutes | -76% |
| Energy Consumption | Baseline | -42% | Significant reduction |
| OEE | 71% | 91% | +20 points |
Business Outcomes
- Retained existing $12M contracts with improved margins
- Won 3 new component programs worth $8.5M annually
- Reduced quality-related costs by $680,000 per year
- Enhanced reputation as precision manufacturing partner
Technical Highlights
Servo Press Advantages
- Programmable Motion: Optimized slide profile for each part geometry
- Dwell Control: Precise bottom-dead-center dwell for material forming
- Tonnage Monitoring: Real-time detection of material variation
- Energy Efficiency: Power consumed only during actual forming
Quality System Features
- Automatic part rejection when parameters exceed limits
- Trend analysis predicting tool wear before quality impact
- Electronic signatures for operator and inspector accountability
- Integration with customer quality portals for direct data sharing
Client Testimonial
“In aerospace, there’s no room for compromise. The servo press system gave us capabilities we simply couldn’t achieve with conventional equipment. The traceability features transformed our audit process—what used to take days now takes hours. Most importantly, we have complete confidence in every part we ship. This investment protected our business and positioned us for growth.”
— VP of Operations, Aerospace Division
Key Success Factors
- Technology Match: Servo press capabilities aligned with aerospace requirements
- System Integration: Seamless connection to existing quality management systems
- Validation Rigor: Comprehensive IQ/OQ/PQ ensuring performance confidence
- Training Excellence: Operators and quality staff fully certified on new systems
- Partnership Approach: Ongoing support and continuous improvement collaboration
Future Expansion
Based on this success, the client has approved capital investment for two additional servo press lines and is exploring automation integration for lights-out production of high-volume components.
Conclusion
This case demonstrates that advanced press technology, when properly integrated with quality systems and supported by comprehensive training, delivers transformative results in demanding aerospace applications. The combination of precision, traceability, and flexibility creates sustainable competitive advantage.
