Case Study: Alcast Company Ensures Seamless Transfer Tooling Solution for AMT & DDC
Overview
When AMT and Detroit Diesel Corporation (DDC) faced a critical supply chain challenge due to the financial collapse of their previous casting supplier, they required a reliable and experienced foundry to take over the production of their permanent mold oil pan casting. A successful transition was essential to maintaining production schedules, ensuring quality, and protecting AMT’s business with the OEM.
Client Challenge
The original Ohio-based foundry responsible for producing the OEM oil pan casting encountered significant financial difficulties, resulting in high scrap rates, production inefficiencies, and an inability to meet quality standards. In early 2023, AMT and DDC invested in a new permanent mold tool to address these issues. However, before production could be fully validated, the foundry went out of business, leaving AMT without an approved casting supplier.
Without a qualified replacement foundry, AMT faced:
- Severe production delays that could impact delivery commitments
- Potential loss of business if the OEM decided to reassign the machining portion of the program
- Significant financial implications due to sunk costs in tooling investment
Transfer Tooling Solution
Having previously worked with Alcast Company on high-volume casting programs, AMT recognized Alcast’s technical expertise, precision manufacturing, and customer-focused approach. Additionally, a key Alcast team member had prior experience with the oil pan program, ensuring a smooth transition.
In August 2024, following the bankruptcy and closure of Reliable Castings, Alcast collaborated with AMT’s VP of Engineering, Bojan Vladusic, and DDC leadership to secure, assess, and adapt the transferred tooling. Alcast’s engineering team conducted a comprehensive evaluation of the existing tool, implemented necessary modifications, and rapidly moved into sample production and validation.
Key factors in Alcast’s successful transition:
- Deep expertise in permanent mold tooling and aluminum casting
- Rapid assessment and modification of transferred tooling
- On-time PPAP sample delivery, ensuring AMT retained control of the program
- Consistent production quality and reliability, mitigating future risks for AMT and DDC
Results
Despite the complexity of the transition and stringent timeline, Alcast successfully:
- Modified and validated the transferred tooling, ensuring it met OEM specifications
- Delivered PPAP-approved samples on time, preventing sourcing changes by the OEM
- Stabilized production, ensuring continuity in AMT’s supply chain
As a result, AMT maintained its contract with DDC and prevented costly disruptions, securing a long-term supply chain solution.
Aluminum Casting Client Testimonial
“Alcast has an outstanding engineering team with deep expertise in permanent mold casting. Their ability to quickly modify, test, and put the new tool into production with minimal disruption was critical to our success. Had Alcast failed to deliver PPAP-approved samples on time, the OEM would have been forced to reassign the casting to another supplier. Alcast met their commitment as promised.”
– Girish | AMT Representative
Conclusion
The successful transfer, modification, and launch of the AMT/DDC oil pan at Alcast Company highlights the importance of working with a stable and experienced manufacturing partner. Alcast’s engineering expertise, speed to market, and commitment to quality not only resolved AMT’s supply chain challenges but also strengthened its position as a trusted strategic supplier.
For more information regarding Alcast Company’s transfer tooling capabilities, click here or contact us now to speak with a transfer tooling expert.