Sand Casting vs. Die Stamping Cost Reduction | Component & Device Sales, Inc.

Our customer had tried to work with two other stampers to make this part and both competitors failed.
The hole alignment on this Safety component is critical in the application for this Over the road truck component.
The Roundness, as well as the alignment of all holes, is critical & they can’t be oval. Oval holes result in a safety failure.
We eliminated the need for the sand casting. Which also removed any concern of possible casting defects such as porosity or shrink in these parts.
We eliminated the need to do the multiple machining operations that were required to drill the 5 required holes. These holes are punched complete in our progressive die with no secondaries required.
By using one of our 7 SERVO presses we were able to produce this part where 2 other competitors had failed.
We designed the tooling, built the tooling and got the PPAP approved before the customer paid for the tooling.
The redesign of this part ended up being over a million dollar cost reduction to the customer based on annual usage.
The conversion to a stamping made this a stronger and more consistent part.
The customer went from a 16 week lead time for and offshore machined casting to a 4 day lead time. Parts are pulled from out of our 30,000 SQFT finished goods warehouse.
The customer was able to dramatically reduce their inventory levels because their lead time was reduced to a week, so their is no longer need to be holding months of inventory.

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A Million Dollar Cost Reduction