Proof of work

Case Studies

Selected precision-manufacturing engagements across EV, Defence and Industrial Automation — with the tolerances, lead times and rejection rates we hit.

Sector

Process

EV Traction Motor Housing — Aluminium 6061-T6

Challenge

OEM needed a thin-wall aluminium motor housing with concentricity ≤ 15 µm across two bearing bores, ramping from 50 prototypes to 2,500 units / month — without retooling.

Solution

Routed through a 5-axis milling partner with in-process probing, paired with a hard-anodising vendor under one TruSkew QAP. Single source of accountability; CMM reports issued per lot.

Result

Tolerance achieved

±10 µm

Lead time

12 days

Rejection rate

0.4%

"They took a housing our previous vendor couldn't hold concentricity on and shipped it lot-after-lot with CMM data. We scaled from pilot to 2,500/month with no requalification."

— Procurement Head, EV OEM · Kolkata· name withheld under NDA

Airborne Sighting Bracket — Ti-6Al-4V

Challenge

Tier-1 defence integrator required Grade-5 titanium brackets with full material traceability, ITAR-grade documentation and zero non-conformance on a 60-day schedule.

Solution

Manufactured under NDA with a vetted aerospace-cert partner. 100% dimensional inspection, 3.1 MTCs, FAIR per AS9102, and tamper-evident lot packaging managed end-to-end by TruSkew.

Result

Tolerance achieved

±8 µm

Lead time

38 days

Rejection rate

0.0%

"FAIR package landed clean on the first submission. Full traceability, tamper-evident packaging, zero deviations — exactly what our airworthiness team needed."

— Quality Manager, Tier-1 Defence Integrator · Bengaluru· name withheld under NDA

Servo Gearbox Output Shaft — EN24 Hardened & Ground

Challenge

Automation OEM was paying premium prices for ground shafts with 6-week lead times and inconsistent surface finish causing premature bearing wear in the field.

Solution

TruSkew re-routed the part through a turning + cylindrical-grinding cell, added induction hardening upstream, and standardised on Ra 0.4 µm with SPC on the grind operation.

Result

Surface finish

Ra 0.4 µm

Lead time

18 days

Cost reduction

−22%

"Bearing failures on the field units stopped after the switch. We cut 22% off unit cost and got the lead time down from six weeks to under three."

— Head of Sourcing, Industrial Automation OEM · Pune· name withheld under NDA

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