Customer Requirement & Initial Situation
- A customer from the Agro Farm Machinery industry approached AMSOL to develop critical parts.
- Their initial request: Manufacture the components using Investment Casting.
- Challenge: Investment casting, though precise, was too costly for their budget and volume requirements.
Limitations of Investment Casting for this Application
- High per-part cost due to complex process.
- Longer cycle times compared to alternative methods.
- Not necessary for the customer’s functional and tolerance requirements.
- Increased total cost of ownership for large-volume agricultural components.
AMSOL’s Engineering Solution
- AMSOL team carried out application study and functional requirement analysis.
- Suggested alternative manufacturing process: Shell Mould Casting.
- Recommended the right material selection to balance strength, durability, and cost.
- Designed the tooling and process flow for optimized shell mould casting production.
Execution Steps by AMSOL
- Analyzed customer’s design for feasibility.
- Compared investment casting vs. shell mould casting in cost, quality, and lead time.
- Developed prototype samples using shell mould casting.
- Performed dimensional and mechanical testing.
- Gained customer approval after trials.
- Moved into production phase with cost-efficient setup.
Achieved Results
- 35% cost reduction compared to investment casting.
- Met all functional and technical requirements of the application.
- Reduced production cycle time for faster deliveries.
- Delivered consistent quality with shell mould casting process.
- Customer confidence gained, leading to long-term business.
Customer Benefits
- Significant savings compared to their initial expectation.
- Simplified supply chain with AMSOL as a trusted advisor and supplier.
- Optimized process tailored to application needs.
- Reliable partner for future component development.
AMSOL’s Value Proposition
This case highlights AMSOL’s ability to:
- Act not only as a manufacturer, but as a process consultant & solution provider.
- Suggest the best-fit process for cost, performance, and application.
- Deliver value-driven solutions that exceed customer expectations.