FlexFab has earned its reputation as a go-to name for heavy-duty engine components. Their fluid and air movement solutions keep engines operation at peak performance, ensuring no loss of air pressure, maintain turbocharger performance, and EGR gas delivery for heavy-duty brands like Volvo Trucks.

So, when their team started sourcing aluminum exhaust components directly from India, the math looked good. Diecast supplier? Check. Lower costs? Check. Quality issues? Too many to ignore.

But behind the spreadsheets, there was a different story: missed specs, critical tolerance issues, and lead times that stretched production schedules to the breaking point. 

FlexFab needed a fix – and fast.

That’s where MES shines. Our goal was clear: Keep the cost advantage FlexFab needed while adding what they didn’t have: 

• Boots-on-the-ground quality oversight
• Engineering expertise
• A supply chain built for speed

The Challenge: When Lower Cost Comes with Higher Risk 

As expected, direct sourcing gave FlexFab the price they wanted. Unfortunately, it also came with four trade-offs that could no longer be ignored: 

• Communication Gaps: Getting critical tolerances right, including threaded hole depth for oxygen sensors, was nearly impossible without on-site quality oversight. 
• Quality Risks: Out-of-spec machining on drilled holes, tap depth, and surface finish jeopardized airflow and emissions performance. 
• Lead Time Delays: Lack of real-time support, tooling changes, and approvals dragged on. 
• Parts Complexity: These weren’t simple parts. They were gravity-cast aluminum elbows for exhaust recirculation, featuring thin walls, continuous openings, and tight tolerances for multiple machined features.

The result? Cost savings evaporated as delays and quality issues piled up.

 The Turning Point: How MES Made It Work

When delays and quality issues began to threaten production, FlexFab realized they needed a supplier who could do more than ship parts. They needed a partner who knew the complexity of their components (and the cost of getting them wrong).

MES brought what was missing: real-time supplier support, engineering precision, and a supply chain that finally worked without driving up costs.

Here’s how we made it happen:

• Boots-on-the-Ground: From tooling approval to final inspection, our on-site team monitored every stage with no surprises.
• Engineering Support Where and When It Counts: We worked closely with FlexFab and our supplier to ensure the threads and depth for the oxygen sensor mounting point met exact specifications. These weren’t “nice-to-have” specs – they were make-or-break features necessary for performance.
• Smarter Supply Chain Processes: Our inventory planning and shipping strategies slashed lead times and eliminated costly rework caused by packaging mistakes.

 The Solution: Smarter Sourcing Without Sacrificing Cost

In typical MES fashion, we didn’t just replace FlexFab’s supplier, we re-imagined their sourcing strategy.

Gravity Casting Expertise 

• Our supplier produced precision aluminum elbows using permanent mold gravity casting, which was ideal for the thin walls and continuous openings required of the part.
• We delivered finished parts with critical features, such as hose-clamp ribs, positive-stop features, mounting holes, and threaded bosses for oxygen sensors. 

Engineering Oversight 

• MES quality engineers in India were at the ready to oversee casting, machining, and finishing.
• We worked closely with FlexFab to tighten drawings, clarify tolerances, and sign off on tooling well before production.
• Our teams focused on thread quality and tap depth, which was a small detail with a big impact on airflow sensor performance.

 Supply Chain Control 

• The MES solution maintained FlexFab’s cost advantage by leveraging our buying power and footprint in India.
• We dramatically cut lead times through better inventory planning and container optimization.
• MES fixed packaging issues (like missing protective caps) that once caused delays and extra cost.

 Ready to Fix Your Sourcing Headaches?

Our partnership with FlexFab proved something very significant in manufacturing: low cost doesn’t have to mean low control.

MES gives you the savings you want with the engineering expertise and quality you can count on.

Ready to turn sourcing frustration into supply chain success? Contact MES today and let’s get started. 

Key Specs 

Component: Aluminum exhaust elbows for Volvo heavy trucks

Process: Permanent Mold Gravity Diecasting

Material: Aluminum alloy

Critical Features:

• Thin-wall geometry for airflow
• Oxygen sensor boss with tight tap depth tolerance
• Ribbing for hose clamps and positive-stop features

Quality Checks: Leak testing, porosity inspection, cleanliness validation, protective caps

Application: Turbocharger exhaust recirculation systems