Case Study | Extending Precision Manufacturing Capabilities for a Leading Malaysian Automotive Supplier

Client Profile

Our client is a leading automotive component manufacturer based in Malaysia, operating two major production sites: one in Malaysia and another in Vietnam. With over 800 CNC turning machines in total, the Malaysian facility focuses on engine-related rotating parts, sleeves, flanges, and fluid connectors, while the Vietnam site specializes in printer shaft components for export markets.

While the client holds strong in-house capabilities in CNC turning, they faced limitations in die casting, plastic injection molding, and high-spec surface treatment, especially for new-generation automotive components.

Project Background

The client was developing a redesigned engine housing unit and encountered several technical and operational challenges:

• Requirement for high-precision aluminum die casting + CNC post-machining + functional coatings

• Strict material traceability and country-of-origin compliance for U.S. and Japanese end customers

• Fast-track low-volume prototyping (10~50 pcs) to test design iterations and tolerances

With our dual-factory presence in China and Malaysia, we offered a flexible, multi-process, multi-region manufacturing solution tailored to meet all technical, compliance, and timeline requirements.

Technical Highlights & Process Capabilities

✅ Die Casting + CNC Precision Machining

• Material: ADC12 aluminum alloy

• Mold design: Moldflow simulation + vacuum die casting to reduce porosity and deformation

• CNC machining: 5-axis centers for multi-surface operations; flatness ≤ 0.03mm, tolerance ±0.01mm

• QC: CMM inspection, air gauge verification, and go/no-go tool coverage

✅ Injection Molding with Metal Inserts

• Material: PA66 + 30% GF (glass fiber) + brass inserts

• Process: Rotary-table vertical insert molding to ensure tight bonding and position accuracy

• Tolerance control: Dimensional variation within ±0.05mm

✅ Surface Treatment Optimization

• Coatings: Hard anodizing (15μm) + PTFE dry film

• Performance: Passed 96-hour neutral salt spray test with no visible corrosion

• Finish: Ra < 0.8μm surface roughness across visible areas

⭐ Project Management Excellence

To ensure a smooth project lifecycle, we assigned a dedicated cross-functional team, including:

• A technical engineer for DFM review and process integration

• A PMC coordinator to align scheduling between our China and Malaysia sites

• A quality engineer (QE) overseeing full-cycle inspection from IQC to FQC

We provided the client with:

• Detailed project milestone plans

• Full FMEA, Control Plan, and PPAP documentation

• Batch-level Cpk analysis and inspection records for traceability

Our transparent, structured approach allowed the client to manage multiple components and suppliers with confidence and efficiency.

⭐ Robust Quality Control System

We operate under the IATF 16949 quality management system, supported by:

• IQC: Spectral analysis for incoming alloy materials

• IPQC: Real-time SPC monitoring on critical dimensions

• FQC: 100% final inspection for appearance and dimensions

• Lab equipment: CMM, roughness tester, salt spray chamber, and hardness testers

For high-sensitivity programs, we offer a dual-layer inspection protocol—internal QA plus customer remote/onsite verification—to ensure zero-defect delivery.

Results & Impact

• Developed and delivered multiple high-precision cast and molded parts

• Met full compliance with U.S. material sourcing restrictions

• Reduced prototyping cycles to 10–15 working days

• Became the client’s strategic partner for die casting, injection molding, CNC machining, and surface finishing

Conclusion

Real manufacturing capability goes beyond equipment—it requires technical understanding, process integration, and strong execution.

With our dual-site production base, extensive multi-process know-how, and proactive project management, we help global clients solve complex engineering and supply chain challenges with confidence and speed.

If you’re seeking a reliable partner to handle precision components across CNC, die casting, plastic molding, and surface treatment—we’re ready to deliver.