Originally Posted by: HK1837 .............................
GMH didn’t really have the capability to do small volume machining. They almost always outsourced it. Almost everything they put into cars came from outside suppliers, they essentially only cast stuff and pressed sheetmetal, and built cars and components from it. When the first few hundred GTS350 manual engines got water damaged they had Repco rebuild them, they didn’t have the ability to do it, or at least to do it economically. Even the minor machining on the bore tops on those final bigger valve XU1 engines was done outside of GMH I believe.
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actually, having spent a number of years working in the engine and transmission plants at Port Melbourne, I would say they had the 'capability' but not the desire.
Their lathes, boring machines, tapping machines.. all totalled an actual engine manufacturing line. Stick a 'fettled' raw v8 block at the end that says 'start ...
and maybe ( I forget actually how long) a naked new clean fully machined engine block (with matching caps) would pop out the other end.
That end would be hooked on the conveyor and wizz across the plant to start the assembly process. With machined (balanced) crank waiting and pistons
already on rods, the machined block would again drop on an assembly line and have the bits fitted to make an engine.
I said capability ... but not the desire. Those various machines could be set up to do just any sort of machining, drilling, threading operation but unlike
todays computer controlled CNC machining centres which take very little, even zero setup and can do up to 16 things * on a piece of metal in one pass,
these GMH production machines took hours to setup, to change setups and first-off scrap rates were horrendous whilst engineers got things 'accurate'.
Why do it... ? when the time for setup will probably be longer than the time to make a batch of 'special' heads?
* I still work in manufacturing.... for a company that makes 3-4 million metal parts a month. All of those go thru computer controlled machining centres
(vastly bigger than the GMH machines) ... feed in a blank piece of metal and up to 16 drilling, threading, boring, indexing, chamfering, surface finish
operations happen in the one place... in one machine. VERY quickly. You get a complete part out the other end that has been laser checked for accuracy...
most dimensions are down to 0.001mm and scrap rates? Month of May ( I got the results today... ) how about 0.03% of all input??
On a machine that makes more than 300,000 parts a month.. break a tool and it takes 3-4 minutes to replace and set up for the next part??
About 20-30 mins ...