Project Overview
Objective:
Support ZF in the industrialization and serial production of a premium-quality suspension control arm, reaching 1.4 million units per year.
Approach:
Design and implement a fully automated, end-to-end manufacturing process – including stamping, cold forging, robotic MAG welding, precision machining, and advanced surface coatings – optimized for cost efficiency, resource management, and minimal waste.
Quality Commitment:
Ensure durability and safety standards required by global OEMs through 100% quality inspection and complete traceability.
Strategic Relevance:
Achieve above-average levels of excellence and quality in a component integrated into several high-end vehicles produced by the BMW Group.
Results
- Developed a robotic manufacturing ecosystem for welding and machining, ensuring process repeatability, reduced scrap, and 100% traceability.
- Delivered a scalable, cost-effective solution that seamlessly integrates all production stages and positions MCG as a trusted Tier 2 partner for critical chassis components.
- Strengthened MCG’s capabilities in selecting the right production technologies, managing outsourcing partnerships, and optimizing logistics and supply chain processes.
- Successfully consolidated serial production volumes at 1.4 million units per year.
Key Expertise
- Technical procurement & supply chain: Integrating external suppliers for sheet metal, cold-forged components, and surface treatments, while maintaining alignment with OEM quality standards.
- Stamping of structural parts: Ensuring repeatability and dimensional accuracy in large-scale production.
- Robotic welding: Achieving consistent penetration and weld strength across long seams (~2 meters) in safety-critical components.
- Machining precision: Meeting tight tolerances required for assembly and vehicle performance.
- Surface protection: Managing advanced coating processes (ZnNi + KTL) to guarantee long-term corrosion resistance.
- Traceability & inspection: Implementing full unit traceability and AI-powered visual inspection systems.
- Logistics & customer integration: Synchronizing deliveries with Tier 1 and OEM schedules while balancing cost and efficiency.
Technical Information
- This assembly consists of two shells, upper and lower, cold-stamped from complex-phase sheet metal in a 3,300-ton press, one bushing sleeve also cold-stamped in a smaller press, and two cold-forged components.
- These are joined together by MAG welding, with a seam of almost two meters. There is also an in-line machining operation to ensure perfect matching and enhance weldability in the bushing sleeve area.
- For anti-corrosion purposes, the part is finally coated with a duplex-coating system with Zinc-Nickel and E-Coating (KTL), before being delivered to our customer.
Manufacturing Processes
- 3.300-ton Stamping
- Machining
- Robotic MAG Welding
- Packaging Dirty-Circuit (before E-Coating)
- E-Coating (KTL)
- Packaging Clean-Circuit (after E-Coating)
- Logistics & delivery
Adrian Muñoz
Senior Manager Purchasing Buyer | ZF Group
“I started working with MCG ten years ago, and I´ve seen the company´s evolution in several ways. But I´m glad to see that commitment and professionalism have not changed.”
More information
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MCG Automotive Commercial Director