Die-Matic’s Engineering Expertise Saves a Tier 1 Automotive Manufacturer Millions of Dollars Annually

The automotive industry is highly competitive. Efficiency, cost-effectiveness, and innovation are essential to success. One Tier 1 automotive company was able to remain competitive with Die-Matic’s help. Whether assisting with new product design or redesigning an existing component, Die-Matic delivered substantial cost savings and improved part design to its customer. Through collaboration with its customer, they provided solutions that not only met but also exceeded expectations.

Redesigning the ABS Module Bracket

The automotive customer designed a two-piece bracket to hold the Anti-lock Braking System (ABS) module. This design required additional labor and hardware, such as nuts, bolts, and screws, to assemble the two brackets together. Before the project launched, the metal stamper’s engineers reviewed the design and proposed a one-piece solution.

By collaborating closely with the customer’s engineers, the metal stamper’s team developed a new design that eliminated the need for hardware and assembly. The original design was over-engineered to resist vibration and maintain strength, but the new one-piece design addressed these concerns while reducing costs by eliminating a number of fastening components and the costly assembly process. Additionally, the stamping team chose a thinner gauge of mild steel, resulting in significant material cost savings.

Finite Element Analysis (FEA) was conducted to validate the structural integrity of the new design before it was approved and validated for production. With a production volume of over a million pieces per year, this innovative redesign saved the automotive manufacturer over $3 million annually.

Converting to a Stamped Part

Another example where Die-Matic saved the company money involved a part previously manufactured as a casting imported to North America from Eastern Europe. The automotive company approached Die-Matic to explore cost-saving opportunities. Die-Matic’s engineers proposed eight different designs to convert the casting into a stamped part.

One of these designs was approved. The improved solution involved stamping two parts and MIG welding them together. Despite the initial investment in tooling, this new process resulted in annual savings of $600,000 for the automotive customer.

Transitioning From an Eyelet Process to Progressive Metal Stamping

During a routine plant visit, a Die-Matic engineer noticed a metal component manufactured from an eyelet process by another vendor. After discussing the part, the engineer requested an opportunity to quote the part using their progressive metal stamping process.

The part in question was 12 million pieces per year. By switching to the progressive metal stamping process, even with the necessary investment in new tooling, the automotive customer realized an annual cost savings of $675,000.

Driving Innovation and Cost-Savings Through Design

While these are only three examples of many, Die-Matic repeatedly demonstrated its ability to innovate and optimize part design and manufacturing processes. Whether addressing a new part design, redesigning an existing part, or transforming a component from a different process to metal stamping, Die-Matic’s expertise and proactive approach leads to remarkable financial benefits for its customers. These successes underscores the value of collaboration and the impact of Die-Matic’s engineering excellence on its customers.