Rear Drive Unit Assembly
In 2004 MKC, a current supplier of gear carriers and axle tubes, proposed a new methodology of casting, machining, and partially assembling the new Rear Drive Unit program that our customer had been awarded. This methodology was less expensive as it incorporated a unique fully automated integration system, drawing on the Company’s design, engineering, tooling, casting, machining, assembly, and automation capabilities. As a result, the customer awarded 100% of the business to MKC for what they had previously considered a core competency. The RDU assembly is a critical part of the vehicle drivetrain and is used on nine different Ford models covering four vehicle platforms, including the Ford Fusion, Edge, Freestyle, Taurus and Escape, the Mercury Milan and Montego, and the Lincoln MKZ, MKS, and MKX.

Courage Twin Crankcase
In early 2005 a company hired an expert to conduct an in-depth analysis to determine the best North American companies with aluminum die casting capabilities. Of the many suppliers analyzed and visited, MKC was identified by them as being the “cream of the cream of the crop”. As a result, MKC quoted and was awarded the crankcase for a new engine program using a special technology to insert heated cylinder liners in the casting machine just prior to casting the crankcases. Based on this technology, MKC was awarded the business. Since then, MKC has also been awarded five other programs. This business is helping MKC achieve its market diversification goal as these programs are sold to the lawn and garden market.

Rocker Pedestals
Our customer purchases finished, machined and assembled rocker pedestals for assembly into the DaimlerChrysler 3.5 Liter V-6 Engine and the new 4.0 Liter V-6 Engine for the Chrysler 300, Magnum, Charger, Challenger & Caravan platforms. The rocker pedestal supports and attaches the valve train actuator assembly, which includes the rocker arms, to operate the intake and exhaust valves for the engines. The original casting supplier declared bankruptcy and the original machining supplier was having difficulty meeting quality standards. Since the parts had to be aluminum due to weight considerations, MKC proposed using its proprietary semi-solid casting process combined with a dedicated, automated machining and assembly system. MKC was awarded 100% of the business.

Inner Primary Housings
Our customer was having significant quality problems with a supplier in the casting of inner primaries. An inner primary is the cover that houses the linkage that joins the transmission to the engine on the motorcycle. MKC proposed to take over this project and solve the quality problems. They accepted MKC’s proposal and awarded this inner primary to MKC in October 1998. Major engineering effort went into the re-design of the tooling required to cast the part, including obtaining the approval to make significant modifications to the inherited design. Today, MKC is the sole supplier for inner primary housings for all the major product lines offered and is considered a strategic supplier. In 2008 MKC will make three different designs.

Oil Filter Adapter Assembly
As a “Green” supplier, MKC was asked to quote a complete subassembly for an oil filter adapter that was an integral part of the new Hi-Feature V6 Engine. (A “Green” supplier is one that has demonstrated it can meet all cost, quality, and delivery expectations.) Upon award of the program, MKC engineering designed an automated cell that incorporated machining, assembly, and testing of the finished subassembly. In addition, MKC established a supply chain to manage the six sub-suppliers and seven components that are purchased to make up the subassembly. MKC began 100% supply in 2006. This program demonstrates MKC’s strategy to produce complete subassemblies for its customers.

Tensioner Bracket
As described previously, MKC is a preferred supplier for inner primaries for many different motorcycle models. Our customer recommended that MKC be one of the suppliers quoting on the tensioner bracket. This bracket maintains tension for the cam shaft timing chain on the motorcycle. Based on this recommendation, MKC quoted the business and was awarded the bracket with production starting in 2006 using a four-axis CNC Horizontal Machining Center with a spindle coolant system in a temperature controlled facility to meet the very tight tolerance requirements on the parts.