Precision Machining & Cost Reduction for a Global Energy Manufacturer
Challenge
A leading manufacturer in the oil and gas industry faced growing challenges in maintaining efficiency across their extensive product portfolio. As a global solutions partner known for developing precision control valves, thermostats, and energy-exchange pumps, the company supports hundreds of complex assemblies that demand consistency, accuracy, and reliability in the field.
The organization’s engineering team was already sourcing high-performance printed circuit boards from Epec Engineered Technologies for various electronic control systems. However, as their assemblies became more intricate and cost pressures increased, they sought a machining and fabrication partner capable of addressing both technical complexity and cost optimization across multiple product lines.
The company’s primary challenge centered on improving manufacturability and reducing costs without sacrificing the quality or performance required for its critical control products. Each assembly contained numerous machined and fabricated components with tight tolerances, specialized materials, and varying production volumes. Internal machining capabilities had reached capacity, and outsourcing select parts required a supplier with proven technical expertise, documentation control, and traceability to support a regulated industry.
The customers’ objectives were clear:
- Streamline the production of several complex machined parts used in control systems and pump assemblies.
- Achieve measurable cost savings through process improvements and design optimization.
- Validate that their manufacturing partner could meet their rigorous technical and quality standards.
Solution
To meet these goals, the company partnered with a precision manufacturing provider within Epec’s extended network that specializes in CNC machining, custom fabrication, and assembly integration for industrial and energy-sector components – Metal Craft Machining. The engineering teams collaborated closely to review existing drawings, tolerances, and material specifications, identifying opportunities for improvement and efficiency.
The project began with an in-depth review of several critical components, including housings and fittings for control valve assemblies. Many of these parts were originally designed for manual setups and required multiple machining operations. By analyzing tool paths, setup times, and material utilization, the manufacturing team developed a plan to simplify machining processes and reduce scrap rates.
Multi-axis CNC machining centers were introduced to perform more operations in a single setup, significantly improving accuracy and repeatability. Specialized workholding fixtures were designed to support tighter geometric tolerances, while advanced inspection tools ensured every part met print requirements. In several cases, engineers also proposed small design adjustments that improved manufacturability without affecting performance.
To further control costs, material procurement and finishing operations were consolidated under a single supplier structure. This integration allowed for reduced lead times, simplified logistics, and improved documentation management. All parts were processed under strict quality protocols, including first article inspection (FAI), in-process checks, and final inspection documentation tailored to the customer’s internal requirements.
The collaboration also extended into design review and prototype validation. The manufacturing partner worked directly with the customer’s engineering department to test new part configurations that could be produced faster and more consistently. This proactive approach demonstrated not only technical capability but also a shared commitment to improving long-term product performance and reliability.
Result
Although the project is ongoing, early results have been highly positive. The customer has realized measurable cost reductions in several product assemblies, primarily driven by process optimization and reduced rework. Improved machining efficiency and integrated inspection routines have led to higher yields and shorter turnaround times.
The partnership has also strengthened the customer’s supply chain by providing a dependable domestic machining source that can respond quickly to engineering changes, forecast adjustments, and production surges. Communication between the two engineering teams has proven invaluable in ensuring that design intent, manufacturability, and quality are aligned from the start of each build.
Perhaps most importantly, this collaboration reinforced the customers’ confidence in expanding their relationship with the Epec family of companies. By combining expertise in both electronic and mechanical component manufacturing, the partnership continues to demonstrate that complex, high-precision assemblies can be produced efficiently and cost-effectively without compromising performance.
The success of this engagement highlights the value of working with a manufacturing partner that not only delivers parts but also contributes engineering insight and process knowledge at every stage. With additional part families now under review for similar optimization, both teams are confident that future projects will yield even greater efficiency gains and long-term value.
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