High Volume Metal Stamping Case Study

Maintaining efficiency and low costs for high volumes

This customer's production needs are 600,000 – 700,00 pieces per year for FIVE different parts. These parts have a uniform shape with slight variations in each design. Parts A and B shown here are almost identical except for the design and dimensions of their bottom lips. The previous supplier was utilizing secondary machining to crimp the lip after the stamping process and this method was expensive and extended the production time.

Ultra’s first improvement was to remove the crimping operation and replace with coining in a progressive die. The customer was reluctant of this modification and with prototyping we successfully proved this manufacturing method delivered the parts as designed.

Ultra’s second improvement was to reduce their capital costs for tooling by consolidating their progressive dies from FIVE to TWO. This was feasible due to the uniform shape and design of the main component for their parts. One progressive die was designed to stamp three separate parts that were grouped together because of a similar design and features; and the other progressive die was designed to stamp the remaining two parts with similar designs and features. The key to these dies was the last station. It was designed and built for easy changeover to one of five different custom stations to finish the stamping process.

These improvements delivered cost-savings in two key areas.

  1. Eliminating secondary machining and then providing that operation in the progressive dies.
  2. Utilizing only two progressive dies eliminates maintenance and labor costs.

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