Guide to Reducing Costs of Metal Stamped Parts

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Learn some of many methods used by engineers and manufacturing companies to reduce the costs of metal stamped parts both before and after a component has been designed. Manor Tool & Manufacturing, based out of Illinois, offers numerous such tips in this comprehensive guide, the full version of which is available on their website: http://stamping.manortool.com/download-your-free-guide-on-how-to-reduce-cost-of-metal-stamped-parts

Engineering

GuidetoReducingCosts
ofMetalStampedParts

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page1of28
AboutTheAuthor
JOHNCREIGHTON
JohnCreightonistheSalesandMarketingManager
atManorTool.Hehasworkedintheindustrialand
manufacturingspaceforover25years,specializing
inmetalstamping,deepdrawnstampingand
progressivediestamping.
9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020
@ManorToolMfg

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page2of28
AboutTheAuthor 1
TableOfContents 2
HowCanYouReduceTheCostPerPart? 3
#1 Material 4
#2DieLifecycle 5
#3Tooling 6
#4QualityControl 7
#5Tolerance 8
#6 SpecificationRequirements 9
#7ProductRequirementsandPerformance 10
#8FactorOfSafety 11
#9ManualRequirements 12
#10ProductDesignChanges 13
#11SimilarComponents/NearDuplicateDesigns 14
#12 GovernmentRegulations 15
#13 SecondaryServices 16
#14Automation 17
#15 ProjectManagement 18
#16 MarketVerticalFamiliarity 19
#17Volume 20
#18LeadTimes 21
#19DeliveryTime 22
#20ReduceScrap 23
#21Shipping 24
#22Packaging 25
#23DesignReview 26
MetalStampingCostReductionChecklist 27
TableOfContents

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page3of28
HowCanYouReduceTheCostPerPart?
Thisguidewillwalkyouthrough23keypointstoreviewandexaminefor
possiblecostsavingsofyourmetalstampedparts.Let’sgetstarted!

Materials
9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page4of28
#1
Whenselectingthematerialfor
yourpartdidyouconsiderallofyour
options?Withcurrentfluctuation
ofmetalpricing,youmaybeableto
findsavingsinanalternativematerial
thatyoudidnotconsiderpreviously.
Frequentlyweareabletosubstitute
1050AnnealedSpringSteelforHSLA
withminordesignmodifications.
Recentlyacustomercontactedus
toreviewtheproductionofanexistingpart.Theywereusing4130Alloy
Steelfortheoriginalcomponentdesignwhenithadtobedurable.The
requirementshavesincechangedandthedurabilityisnolongeranissue.
ToreducethecostofthecomponentwerecommendedCommercial
Quality(CQ)Steelasareplacement.
Dependingoncurrentmaterialpricesandcomponentrequirements,
makingamaterialchangemayallowyoutorealizesomequicksavings
whilemaintainingthestructuralrequirementsofthecomponent.

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page5of28
Howoftenareyourcurrentdiestaken
offlineforrepairandre-tooling?
Ifyourcurrentdesignrequires
frequentofflinetimefordierepair,
haveyoubeenabletodeterminethe
featuresthatarecausingthisdown
timeandtheleadtimeextension?
Reviewyourdesigntodeterminethepossibilityofalteringthesefeatures
tosimplifythecomponentandeliminateunnecessarywearonyourdieand
tooling.Manor’sengineeringstaffcanaidyourteamwithissueslikethese.
DieLifecycle#2
Theautomotiveindustryspendsanestimated$700millionayear
ondesigning,testing,andcorrectingnewdiesforitslatestmodels.
Abouthalfofthetotalcostgoesforremedyingunanticipatederrors
manifestedaswrinkles,splits,excessivethinning,orotherdefects.”
Source:StampingOutDieDefects,AmericanMachinist,11/1/2003
“

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page6of28
Reviewyourcurrenttoolingrequirementsforyourcomponentsand
determineiftherearealterationsthatcanbemadetoreducecomplexity
andmaintainfunctionality.Forexample,changingsquareholestocircular
holesdrasticallysimplifiesmachiningandtoolingrequirements.Thiswill
reduceyourproductiontimeandyouroverallcomponentcost.Review
yourdesignandoutlinethenumberofmachinesandprocessesthatare
required.Canchangesbemadetoutilizethesamemachineryorprocess?
Manor’sengineeringstaffhashelpedimplementchangesintoolingtosave
customersmoneyontheirparts.
Tooling#3

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page27of28
Material
DieLifecycle
Tooling
QualityControl
Tolerance
SpecificationRequirements
ProductPerformance
Requirements
FactoryofSafety
ManualRequirements
ProductDesignChanges
SimilarComponents
DesignReview
GovernmentRegulations
SecondaryServices
Automation
ProjectManagement
MarketFamiliarity
Volume
LeadTime
DeliveryTime
ReduceScrap
Shipping
Packaging
MetalStampingCostReductionChecklist

9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page28of28
Havesomenewideasonhowtosavemoneyon
yourparts?Scheduleameetingwitha
ManorToolengineerNOWtoreview!
Likewhatyouread?
GetmoreinformationfromJohnCreighton’sbloghere:
View John’s Blog
Request A Quote

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Guide to Reducing Costs of Metal Stamped Parts

1. GuidetoReducingCosts ofMetalStampedParts

2. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page1of28 AboutTheAuthor JOHNCREIGHTON JohnCreightonistheSalesandMarketingManager atManorTool.Hehasworkedintheindustrialand manufacturingspaceforover25years,specializing inmetalstamping,deepdrawnstampingand progressivediestamping. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020 @ManorToolMfg

3. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page2of28 AboutTheAuthor 1 TableOfContents 2 HowCanYouReduceTheCostPerPart? 3 #1 Material 4 #2DieLifecycle 5 #3Tooling 6 #4QualityControl 7 #5Tolerance 8 #6 SpecificationRequirements 9 #7ProductRequirementsandPerformance 10 #8FactorOfSafety 11 #9ManualRequirements 12 #10ProductDesignChanges 13 #11SimilarComponents/NearDuplicateDesigns 14 #12 GovernmentRegulations 15 #13 SecondaryServices 16 #14Automation 17 #15 ProjectManagement 18 #16 MarketVerticalFamiliarity 19 #17Volume 20 #18LeadTimes 21 #19DeliveryTime 22 #20ReduceScrap 23 #21Shipping 24 #22Packaging 25 #23DesignReview 26 MetalStampingCostReductionChecklist 27 TableOfContents

4. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page3of28 HowCanYouReduceTheCostPerPart? Thisguidewillwalkyouthrough23keypointstoreviewandexaminefor possiblecostsavingsofyourmetalstampedparts.Let’sgetstarted!

5. Materials 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page4of28 #1 Whenselectingthematerialfor yourpartdidyouconsiderallofyour options?Withcurrentfluctuation ofmetalpricing,youmaybeableto findsavingsinanalternativematerial thatyoudidnotconsiderpreviously. Frequentlyweareabletosubstitute 1050AnnealedSpringSteelforHSLA withminordesignmodifications. Recentlyacustomercontactedus toreviewtheproductionofanexistingpart.Theywereusing4130Alloy Steelfortheoriginalcomponentdesignwhenithadtobedurable.The requirementshavesincechangedandthedurabilityisnolongeranissue. ToreducethecostofthecomponentwerecommendedCommercial Quality(CQ)Steelasareplacement. Dependingoncurrentmaterialpricesandcomponentrequirements, makingamaterialchangemayallowyoutorealizesomequicksavings whilemaintainingthestructuralrequirementsofthecomponent.

6. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page5of28 Howoftenareyourcurrentdiestaken offlineforrepairandre-tooling? Ifyourcurrentdesignrequires frequentofflinetimefordierepair, haveyoubeenabletodeterminethe featuresthatarecausingthisdown timeandtheleadtimeextension? Reviewyourdesigntodeterminethepossibilityofalteringthesefeatures tosimplifythecomponentandeliminateunnecessarywearonyourdieand tooling.Manor’sengineeringstaffcanaidyourteamwithissueslikethese. DieLifecycle#2 Theautomotiveindustryspendsanestimated$700millionayear ondesigning,testing,andcorrectingnewdiesforitslatestmodels. Abouthalfofthetotalcostgoesforremedyingunanticipatederrors manifestedaswrinkles,splits,excessivethinning,orotherdefects.” Source:StampingOutDieDefects,AmericanMachinist,11/1/2003 “

7. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page6of28 Reviewyourcurrenttoolingrequirementsforyourcomponentsand determineiftherearealterationsthatcanbemadetoreducecomplexity andmaintainfunctionality.Forexample,changingsquareholestocircular holesdrasticallysimplifiesmachiningandtoolingrequirements.Thiswill reduceyourproductiontimeandyouroverallcomponentcost.Review yourdesignandoutlinethenumberofmachinesandprocessesthatare required.Canchangesbemadetoutilizethesamemachineryorprocess? Manor’sengineeringstaffhashelpedimplementchangesintoolingtosave customersmoneyontheirparts. Tooling#3

8. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page27of28 Material DieLifecycle Tooling QualityControl Tolerance SpecificationRequirements ProductPerformance Requirements FactoryofSafety ManualRequirements ProductDesignChanges SimilarComponents DesignReview GovernmentRegulations SecondaryServices Automation ProjectManagement MarketFamiliarity Volume LeadTime DeliveryTime ReduceScrap Shipping Packaging MetalStampingCostReductionChecklist

9. 9200IvanhoeStreet,SchillerPark,IL60176 www.ManorTool.com Manor@ManorTool.com 847-678-2020Page28of28 Havesomenewideasonhowtosavemoneyon yourparts?Scheduleameetingwitha ManorToolengineerNOWtoreview! Likewhatyouread? GetmoreinformationfromJohnCreighton’sbloghere: View John’s Blog Request A Quote

Guide to Reducing Costs of Metal Stamped Parts

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