Achieving Quality, Efficiency and Cost Excellence in Motorcycle Crankcase Manufacturing
This case covers Tianxin's successful production of complex crankcases for Tianma Group. Key results include a 30% cut in setup time, 100% FAI pass rate, defect rate below 1%, monthly output of 15,000 units, and 10% overall cost reduction.
Case Details
Founded in 1995, Guangzhou Tianma Group is a leading private motorcycle manufacturer prioritized and supported by the Guangzhou municipal government. Its core subsidiary has long been engaged in motorcycle R&D and production. The company’s products sell well across China and are exported to Southeast Asia, the Middle East, South Africa, the Americas, Europe and other regions, with a well-established overseas market presence. In 2015, thanks to its mature CNC precision machining technology, Tianxin Precision Manufacturing became a preferred supplier of Tianma Group. The two parties launched cooperation on the crankcase project for motorcycle gasoline engines. Tianxin Precision participated in the project bidding and commenced prototype production.
The crankcase features a complex structure with 37 mounting points in total, which requires multi-axis machining. The critical bore diameter is ø68 mm with a strict tolerance of 0 to 0.015 mm, demanding extremely high machining precision. In addition, the project was on a tight schedule: the whole process from prototype approval to mass production had to be completed within just two months.
To ensure smooth project delivery, our technical team conducted a comprehensive Design Failure Mode and Effects Analysis (DFMEA) to identify potential production risks in advance. ADC12 aluminum alloy was selected for the product, which boasts excellent castability and machinability. After surface treatments including painting and passivation, the finished product fully meets the client’s requirements. We adopted 4-axis horizontal machining centers equipped with power tools for production. Compared with traditional 3-axis equipment, the tooling setup time was cut by 30%, greatly boosting production efficiency.
All 74 dimensional indicators passed the First Article Inspection (FAI) at the first attempt. Currently, the product defect rate is steadily kept below 1%, with a monthly output of 15,000 units. Through continuous process optimization and technological upgrading, the overall production cost has been reduced by 10%. We have achieved remarkable improvements in product quality, production efficiency and cost control.
