Ford Explorer electric model: how we delivered the window-regulator component project
The production of the FORD CX470 component family stands as the largest and most complex automotive project in Mitter’s history. Over the course of more than eighteen months of preparation and manufacturing, we faced significant engineering challenges while introducing numerous new technologies, machines and competencies into the company. The project became a true milestone: it included the construction of the largest tool we have ever built, required major investments to support series production, and marked the launch of our first large-scale robotized manufacturing process.
Starting point: high expectations, high stakes
We knew from the very beginning that this would not be a conventional project. The customer requirements were extremely strict, with tolerance limits that were often challenging to achieve. Even in the prototype phase, extensive coordination was needed, as we worked closely with the customer to fine-tune critical dimensions and measurement methods.
The complexity and scale of the project are further illustrated by the fact that two of the three tools required the involvement of external designers, and several process steps were supported by subcontractors during the series-tool manufacturing phase. This approach enabled us to keep the project on schedule without compromising the service provided to our other customers.
Delivering this project required an exceptionally intensive and highly flexible level of teamwork across all functions.
According to our engineers, these tools were true “textbook cases” of engineering complexity.
Three tools were manufactured for series production, each corresponding to a different component:
- two 2-cavity tools for the larger parts,
- and one 4-cavity tool for the smaller but highly complex part – which ultimately became the largest tool ever produced in Mitter’s history, weighing 4,800 kg.
All three tools operate with a valve-gated hot runner system, as the material is long glass fiber reinforced PP. Injection molding simulations conducted at the beginning of the project confirmed that optimal filling and acceptable weld line quality could only be achieved using cascade gating.
According to our engineers, these tools were true engineering “textbook cases,” featuring:
- mechanical slides,
- hydraulically actuated core pins,
- insert-holding blocks,
- and a highly complex, segmented cooling system.
The cooling system of the 4-cavity tool is so intricate that the cooling lines must be disconnected and dismantled before every tool change — a separate operation in itself. Due to its size, the tool fits only narrowly between the columns of our new Demag 650 injection molding machine.
Investments: new machinery, new crane, new competencies
The implementation of the project required significant investments.
- We acquired a Demag 650 electric injection molding machine equipped with a specialized screw capable of processing long glass fiber reinforced material with minimal fiber damage.
- To handle the large tools, we built a new crane track and installed a new overhead crane.
- We also installed a Sepro robot and multiple temperature control units to ensure precise thermal regulation.
This project marked our first major robotized production process, bringing new competencies and a renewed technological mindset into our daily operations.
Series production: from first deliveries to stable operation
The first actual series delivery took place in May 2024.
As expected, the start of production did not come without challenges:
fine-tuning the robots required time, resulting in a higher initial scrap rate,
the three products together required managing 902 measurement points — a substantial task,
the design of the measurement jigs and the refinement of the measurement programs were carried out in close cooperation with the customer, supported by weekly online meetings and monthly on-site reviews.
In terms of cycle time, we achieved an average improvement of 10% across all three products compared with the initial values. It is important to highlight that this improvement did not come from exceeding technological limits but from the fact that the robot’s initial safety settings resulted in a higher starting cycle time than planned. Once we fine-tuned the robot operation based on real production experience, we reached the cycle times committed in our quotation.
After overcoming the early challenges, series production gradually stabilized and today runs smoothly and predictably.
Lessons learned
The CX470 project brought significant internal development:
the acquisition of a brand-new electric injection molding machine and an expanded production infrastructure,
the introduction of a complex robotized manufacturing process,
strengthened engineering and quality assurance competencies,
and valuable experience gained from working with external specialists.
For our team members, the project represented not only a technical challenge but also a human one.
According to one team member, “It was both a major challenge and an inspiring task.” Another noted: “We have never had this many customer meetings during a single project.”
From milestone to springboard
As a result of all these efforts, the project successfully transitioned into full series production, and continues to run reliably and at consistently high quality. Beyond achieving strong customer satisfaction, the project also contributed significantly to Mitter’s internal development, building knowledge and competencies that will support future large-scale projects.
For Mitter, the CX470 project was a true milestone: it demonstrated our capability to deliver even the most complex automotive manufacturing challenges. The expertise and experience gained throughout the project now provide a solid foundation for approaching future complex projects with even greater confidence.
