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From 5 dies to 1
How a Single Progressive Die Transformed Circuit Breaker Production
The Client
A leading electrical manufacturer specializing in circuit protection devices, including circuit breakers used in residential, commercial, and industrial applications. Their products are known for high reliability, safety, and compliance with industry standards.
As demand for their circuit breaker assemblies increased, the company faced serious production inefficiencies that limited their ability to scale operations efficiently.
The Challenge
The client’s manufacturing process for a single circuit breaker assembly relied on five separate progressive stamping dies, each producing different components that required manual assembly afterward.
This setup caused multiple issues:
High labor costs—each part had to be moved, assembled, riveted, and tapped manually, adding unnecessary labor time. Material waste—handling multiple coils for separate dies increased scrap and inefficiencies. Production bottlenecks—the multiple die process limited capacity and throughput, making it difficult to scale production. Quality inconsistencies—manual assembly increased the risk of defects and misalignment. Complex inventory management—tracking and sourcing multiple part numbers added logistical challenges.
The client needed a streamlined, high-efficiency solution that could reduce manual labor, improve quality, and increase production output without expanding their workforce.
The Gromax Solution
To address these challenges, our engineering team completely redesigned the client’s tooling approach, replacing five progressive dies with a single high-efficiency progressive die system.
Key Features of the Solution:
Single Progressive Die Consolidation – Instead of five separate dies, we engineered a single progressive die that produced the entire circuit breaker assembly in one process. Multi-Coil Material Integration – Re-designed to simutaneously handle multiple materials in a single die, reducing handling time and material waste. In-Die Thread Tapping – Eliminated the need for secondary tapping operations and hand riveting, saving labor hours and improving consistency.
Fully Assembled Output from the Press – The part exited the press completely formed and assembled, removing manual assembly steps. Hard Tooling for Precision & Consistency – Ensured that every part met exact specifications, eliminating defects caused by manual processes.
This solution transformed the client’s production method, allowing them to scale operations efficiently while maintaining exceptional quality standards.
The Results
The impact of switching to a single, multi-material, progressive die system was immediate and measurable:
90% reduction in labor costs – Eliminating manual assembly and separate tapping, and riveting operations significantly lowered workforce expenses.
Increased production capacity – Higher throughput with fewer machine setups and material handling steps.
Reduced material waste – Optimized stamping efficiency lowered scrap rates, leading to substantial cost savings.
Improved product consistency – Hard tooling ensured uniform quality and precision, reducing defect rates and rework.
Simplified inventory management – Consolidating dies reduced part numbers, making procurement and logistics more efficient.
This transformation allowed the client to meet growing demand, improve product quality, and significantly reduce costs, all without increasing factory space or adding extra workers.
Key Takeaways
By revolutionizing the tooling approach, we helped a leading electrical manufacturer:
Eliminate multiple progressive dies and consolidate production into a single, efficient process. Integrate in-die thread tapping and riveting to remove secondary labor-intensive operations. Improve production speed and reduce labor costs while enhancing quality consistency. Reduce material waste by optimizing material flow within a single progressive die. Simplify inventory management by decreasing part numbers and supply chain complexity.
This solution positioned the client for long-term success, allowing them to scale production without increasing costs—giving them a strong competitive edge in the electrical manufacturing industry.
Gromax Precision Die & Mfg., Inc. specializes in designing and manufacturing precision metal stamped parts and tooling, including progressive stamping dies and custom equipment. With an on-time delivery rate of 99.68% and a defect rate of just 0.066%, the company ensures exceptional reliability and quality.
Gromax is ISO 9001:2015 certified and ITAR registered, serving industries such as medical, defense, aerospace, industrial automation, and automotive with high-quality, innovative solutions.
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