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Late in 2009 a team of manufacturing engineers from s Japanese OEM met to review their latest powertrain project, a new four-cylinder engine to be used in one of the company's strongest selling platforms. The manufacturing plan was to integrate vertically--from casting to assembly--and the cylinder block casting process step was of particular concern.
Based on experience the team knew the leak-test requirements would be difficult to meet without vacuum impregnation, but their experience also led them to believe impregnation service suppliers were short on effective solutions. Traditional basket "batching" systems would not integrate into their modern assembly plant, and the …