Stamping Collaboration Cost Reduction
Introduction
Based on the success of previous collaborations, engineers from a Heavy Equipment manufacturer approached KMC for a lower cost alternative to a traditionally high-cost casting. The goal was to eliminate excess costs through changes to the manufacturing process without compromising performance.
Challenges
The manufacturer sought to reduce the cost of a specific component previously made using cast powdered metal and extensive machining operations. Their existing process was expensive, with estimates ranging between $130–$150 per part. They needed:
- A lower-cost solution
- A partner with proven manufacturing innovation
- Confidence that performance would not be compromised
Solution
KMC proposed and implemented a stamping-focused redesign:
- Utilized a laser-cut blank to ensure precision and material efficiency
- Consolidated forming, center piercing, and perimeter trimming into a single die operation
- Subcontracted cleaning, rust protection, and 100% gauge-based inspection and sorting
- Several design iterations were made to ensure the stamped part met or exceeded performance expectations
Conclusion
The results delivered measurable impact:
- Approximate part savings of $882,000, improving the manufacturer’s bottom line
- Greater productivity through streamlined production
- Over 14,000 parts sold since 2018
- Tooling investment was offset by long-term savings
KMC brought forward an innovative manufacturing solution that directly addressed the manufacturer’s cost and performance goals solidifying KMC’s role as one of their trusted suppliers.
