Preparing a Critical Rotor Housing for Scalable Production 

Most manufacturing inefficiencies remain invisible as long as production continues and parts arrive when expected.  

That was the case for Thompson Pump, a manufacturer of hydraulic pumps used across construction, industrial, oil, and gas applications where reliability under pressure is non-negotiable. In one of its systems, performance depends on a large aluminum rotor housing that must consistently perform in demanding environments.  

The part had been produced by the same supplier for years, but long lead times and small production runs made it increasingly difficult to get parts when needed. This prompted Thompson to reach out to MES for help.  

MES began by examining how the part moved through Thompson’s supply chain, reviewing batch quantities, container usage, inventory location, and quality expectations. 

The review revealed several inefficiencies, including:  

• Small production runs that drove underutilized containers 
• Overseas inventory that wasn’t readily accessible 
• Undocumented or inconsistently defined quality and testing requirements

By partnering with MES Inc., Thompson gained clearer visibility into the constraints of its existing supply setup, as well as a more controlled approach to preparing the part for future production needs. 

Application Overview and Rotor Housing Performance Requirements 

Because the Thompson 74S8603 aluminum rotor housing operates in high-pressure hydraulic environments, leak performance is not just a functional requirement. It’s a safety one. Any porosity, dimensional variation, or sealing issue can compromise performance and introduce risk. 

From a manufacturing standpoint, the part presents several inherent challenges due to its size, material, and function: 

• Aluminum A356 gravity casting 
• Machined and tested after casting 
• Approximate dimensions of 26 × 19 × 16 inches 
• Weight of roughly 63 kilograms 

Feasibility Review and Quality Definition  

As MES evaluated the rotor housing, it became clear that its physical characteristics and application demands required a more formal feasibility and quality definition than had previously existed. 

The size and mass of the casting increase sensitivity to flow behavior and wall thickness variation. Machining consistency is critical to maintaining sealing surfaces and internal alignment. Porosity in pressure-bearing areas creates both functional and safety risk. 

Leak performance was expected for this housing, but MES identified a critical gap: a documented, repeatable leak-testing procedure did not exist. Testing expectations had been applied informally, but without a defined standard that could be consistently executed or validated as production needs change. 

MES’s detailed documentation review revealed additional risks:  

• Mismatches between 2D drawings and 3D models 
• Dimensions defined in one format but missing in the other 
• Ambiguity around inspection and acceptance criteria

Rather than proceeding with incomplete definitions, MES focused on clarifying requirements before scale through:  

• Feature-by-feature dimensional review 
• Laser scanning and dimensional reporting 
• Identification of tooling adjustments for high-risk areas 
• Weekly collaboration on tooling, quality, and testing requirements 

By formalizing requirements that had previously been assumed, MES helped transform an established part into one that could be produced and validated with greater control. 

This work established a clearer foundation for:  

• Repeatable manufacturing 
• Consistent quality verification 
• More predictable production ramp-up

Reworking the Supplier Model and Logistics Approach 

With feasibility and quality requirements clarified, attention shifted to the supplier model supporting the part.  

The existing setup relied on small production runs, often limited to 10 to 20 units at a time, placed on underutilized containers. Inventory remained overseas, and long lead times were accepted as part of the process.  

MES evaluated production, shipping, and inventory as a single system rather than isolated variables. This revealed that inefficiencies were driven by a logistics model never designed to support small, variable orders efficiently. 

Because MES manages regular container shipments across multiple customers and suppliers, Thompson’s parts could be integrated into an existing logistics flow rather than shipped independently. MES also assumed responsibility for coordinating production timing, container planning, and inventory strategy. 

Although the project has not yet entered mass production, this reworked model established a clearer framework for how the part will move as volumes increase, replacing a reactive shipment-by-shipment approach with one built for coordination and control. 

Current Status and Path to Production  

At the time of this case study, the rotor housing project remains in the pre-production phase. Initial samples have been produced and are under review, with additional tooling adjustments planned based on feasibility findings and dimensional validation. 

The incumbent supplier continues to produce parts to avoid supply interruption. In parallel, MES and Thompson are working through a structured transition plan that includes final sample approval, production timing, and container planning. 

Through feasibility review, quality definition, and supplier model restructuring, the part is now supported by clearer specifications, documented testing expectations, and a logistics framework designed to avoid previous inefficiencies. 

When production transitions, Thompson will move into a supply setup with greater visibility, more predictable logistics, and tighter control over a safety-critical component. The partnership also establishes a foundation for future collaboration, including discussions around supplying the same cast parts in painted condition. 

For Thompson, the value of this collaboration lies in what was addressed before scaling production: ambiguity, inefficiency, and unmanaged risk. For MES, it reflects a core principle of our approach: fixing the system so production can scale without surprise. 

Want to learn more about how MES helps manufacturers prepare complex components for production while reducing logistics friction? Contact us.  

Project Snapshot  

• Customer: Thompson Pump 
• Industry: Construction and industrial hydraulic equipment 
• Component: 74S8603 aluminum rotor housing 
• Application: Hydraulic pump assemblies 
• Manufacturing Process: Aluminum gravity casting with machining and leak testing 
• Material: Aluminum A356 
• Part Size and Weight: Approximately 26 × 19 × 16 inches; ~63 kg 
• MES Scope: Sourcing, manufacturing, quality definition, global logistics, and inventory planning 
• Project Status: Pre-production; samples under review with production transition planned 
• Quality & Compliance: ISO 9001-certified systems; IMMEX / VAT-compliant cross-border manufacturing 
• Business Outcome: Restored production continuity