ANONYMIZED PROJECT CASE
A German industrial valve customer contained an assembly-fit nonconformance on an ADC12 die-cast bracket by defining the affected feature, introducing a dedicated check gauge and applying 100% verification before later shipments.
PART & APPLICATION
The bracket supports an industrial fluid-control valve assembly. Its mounting and mating features must remain compatible with downstream customer assembly even when shipping and assembly feedback arrive after the next batch has entered production.
PROJECT REQUIREMENT
The German customer required an ADC12 die-cast valve bracket that matched the released drawing and assembled consistently with the downstream valve system. Typical demand was two orders per year, with approximately 500 to 800 pieces per shipment.
Exact dimensions, datums and acceptance values remain confidential.
MANUFACTURING CHALLENGE
The sample stage identified a draft-angle issue, which the two parties reviewed and agreed before production. A later customer assembly then exposed a separate undersized feature that had not been detected during sample approval.
Because shipping and assembly feedback were delayed, the following batch had already been produced when the earlier nonconformance was confirmed. The response therefore needed both commercial containment and a reliable production check for all later shipments.
MANUFACTURING ROUTE
The primary process and supporting operations are shown as one connected route.
The response separated the sample-stage draft agreement from the later production dimensional nonconformance. The supplier accepted the cost associated with the affected parts, identified the assembly-critical characteristic and developed a dedicated gauge for repeat verification.
The later release route required 100% checking of that feature before shipment, providing a direct control linked to the customer assembly problem.
Part function, controlled dimensions and acceptance needs.
High-pressure aluminum die casting for repeat component production, supported by tooling review, trimming, CNC machining, finishing and project-specific…
Evidence checked against the agreed project scope.
TOOLING & SAMPLE APPROVAL
The first samples prompted a joint review of draft requirements and the parties agreed the released condition. After production began, downstream assembly revealed a separate dimensional issue that had not been identified at the sample stage.
The affected feature was then isolated for dedicated verification before later batch release.
QUALITY & VERIFICATION
The corrective control focused on the feature linked to the customer assembly nonconformance. A dedicated physical check gauge was defined and the affected feature was inspected on every part before shipment.
The photograph includes measurement examples, but all controlled dimensions, datums and measurement instructions remain governed by the approved drawing and inspection plan.
The customer identified an undersized feature during downstream assembly after the production batch had shipped.
Outcome: The feature was treated as a formal nonconformance and separated from the earlier draft-angle agreement.
A physical check gauge was created for the affected assembly characteristic.
Outcome: The feature could be checked consistently without relying only on periodic caliper sampling.
Every later bracket was checked at the identified feature before shipment.
Outcome: The revised inspection route was used to close the recurring risk recorded in the nonconformance.
PROJECT RESULT
The project continued under a revised inspection route using the dedicated gauge and 100% verification of the affected feature. The case demonstrates traceable containment and corrective control rather than claiming that dimensional risk can be eliminated from all future parts.
No rejection-rate percentage, saving or universal tolerance is published because no approved supporting record was supplied.
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ENGINEERING REVIEW
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