Sustained Cost Reduction in Volume Production
Sustainable total-cost reduction for volume production, from CNC-to-cold-heading conversion to part consolidation.
Once a product is in volume production, the biggest savings usually stop coming from design and start coming from process. Our continuous process optimisation service reviews how a fastener is made, assembled and qualified, then attacks the cost that remains — without compromising the function that was already validated.
Typical levers include converting a CNC machined part to cold heading where simulation analysis shows the geometry allows it, refining process parameters to raise throughput, and consolidating several components into one multi-functional product. Published expectations are a 20% cost reduction from CNC to cold heading conversion and a 10% total-cost-of-ownership optimisation through parameter and assembly refinement.
Scope & Deliverables
Everything included when you engage this service
Cost Reduction Methods
- Process optimization (e.g., CNC to Cold Heading conversion via simulation analysis)
- Efficiency gains via parameter adjustment (e.g., case study: 375k RMB annual savings)
- Consolidating multiple components into multi-functional products
- Exploring additional optimization avenues
Potential Savings Opportunities
- Estimated 20% cost reduction by converting CNC to Cold Heading
- Estimated 10% TCO optimization through parameter and assembly refinement
What You Can Expect
Figures from our published service commitments
How We Work Together
A short, low-friction path from first contact to result
Pick the volume part
A high-runner fastener or sub-assembly where cost matters most.
Process simulation
We test whether cold heading or parameter changes can hold the geometry.
Tooling and trial
Tooling built and samples validated against the original specification.
Roll out savings
Production switched over and the saving tracked against baseline.
Case Study: Real-World Optimization
A published example of a cold-heading conversion
Optimization Strategy
- Converting blanking to cold heading process; increasing forming space and changing material to 10B21.
- Replacing 4x R5.0 corners with straight edges; adding R0.8 at the base and optimizing fillet R.
Cost-Saving Results
- Tooling Cost: 78,000 RMB
- MOQ: 100k units; Total volume: 500k units
- Unit cost reduced by 0.75 RMB; Total savings: 375,000 RMB.
Other Technical Services
Combine services for a faster, cheaper product programme
Take cost out of your volume parts
Send us a high-volume part and we will show you which process change delivers the next round of savings.
Talk to Our Engineers