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Tooling Upgrade
How Smarter Dies Cut Costs and Increased Production Efficiency
The Client
A leading industrial components manufacturer specializing in precision copper and red metal parts used in electrical, automotive, and industrial applications. Their products require high conductivity, durability, and precision stamping to meet strict industry and customer specifications.
The company had been sourcing components from a supplier using outdated tooling and manual processes, which led to higher costs, inefficiencies, and labor-intensive production. To remain competitive, they needed a more efficient, cost-effective solution.
The Challenge
The client’s supplier was producing copper parts using rudimentary tooling, which created several key challenges:
🔴 Manual labor dependency – Operators had to hand-feed copper blanks into basic dies, increasing labor costs and slowing production.
🔴 Limited output per cycle – The existing die could only produce one part at a time, reducing throughput.
🔴 Higher per-piece costs – Inefficiencies in production led to higher costs per unit, making it difficult to meet customer cost targets.
🔴 Scalability concerns – As demand increased, the manual feeding process and slow cycle times created bottlenecks in production capacity.
The client needed a modernized tooling solution that could increase efficiency, reduce labor costs, and bring down part prices to remain competitive.
The Gromax Solution
To address these inefficiencies, we redesigned the tooling system and implemented a high-efficiency progressive die solution that:
✅ Replaced manual feeding with fully automated progressive dies – Eliminating the need for operators to hand-feed blanks, reducing labor costs significantly.
✅ Increased production output – The new tooling produced multiple parts per cycle, dramatically improving efficiency.
✅ Optimized material usage – The progressive dies reduced material waste, cutting down on overall costs.
✅ Lowered per-piece costs – The higher efficiency and labor reduction enabled the client to achieve their customer’s cost targets.
✅ Provided a fast return on investment – The new tooling was designed to pay for itself in under 20 months through savings in labor and production costs.
By moving to automated, precision tooling, we helped the client increase production speed, reduce costs, and improve overall manufacturing efficiency.
The Results
The transition to advanced progressive dies delivered immediate and measurable benefits:
📉 Eliminated manual labor costs – Fully automated tooling removed operator feeding, reducing labor expenses.
🚀 Boosted production efficiency – The ability to produce multiple parts per cycle significantly increased throughput.
💰 Lowered part costs – More efficient manufacturing brought down per-piece pricing, helping the client meet their customer’s cost targets.
✔️ Achieved rapid ROI – The investment in tooling paid for itself in less than 20 months through operational savings.
🔄 Scalability for future growth – The upgraded tooling system allowed for increased production capacity without additional workforce expansion.
By replacing outdated, labor-intensive tooling with a high-efficiency progressive die system, the client secured a competitive edge in their market, ensuring they could meet increasing demand while keeping costs low.
Key Takeaways
By modernizing the client’s stamping process, we helped them:
✔️ Eliminate manual feeding and reduce labor costs
✔️ Increase production efficiency with high-speed progressive dies
✔️ Lower per-part costs to meet customer pricing targets
✔️ Reduce material waste and improve overall cost-effectiveness
✔️ Achieve full tooling ROI in under 20 months
This case study proves that investing in smarter tooling solutions leads to long-term cost savings, increased production efficiency, and stronger competitiveness in precision manufacturing.
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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