Automotive industry

Application:

Chassis

Component:

Brake disc cover plates

Task:

Cost savings over existing designs

Requirement:

Cost savings to be considered through the reduction of materials used, lower expenditure on production and reduced tool costs

Challenge:

1) Due to the design of the pulling direction with corresponding measurements, the high material usage results in -> high material waste
2)Due to the previous manufacturing procedure, between 12 and 14 work steps were necessary
 

Solution:

The pulling direction of components was optimised by empirical test series such that up to 15% of the material weight could be saved. Due to the change in pulling direction, savings could be realised in the tools, which allowed around 15% of the work stages necessary up to that point to be dispensed with.

Success:

Cost reductions of 5-10% were sustainably achieved