Maximizing Efficiency with Progressive Tooling: A Case Study

How INDUSTRY TOOLING Helped an Automotive Supplier Reduce Production Time by 30%

When it comes to high-volume manufacturing, every second counts. One of our recent clients, a Tier 1 automotive supplier, approached us with a challenge: their existing production process was slow, costly, and prone to inconsistencies.

They needed a tooling solution that would increase production speed, reduce waste, and improve part quality.

The Challenge:

The client was producing a metal automotive bracket using three separate tooling setups. This led to:

• Long production cycles

• Increased handling and labor

• Quality variations between batches

• High material waste due to inefficient strip layouts

Our Solution:

We proposed a custom progressive tool that would combine all operations—piercing, forming, and trimming—into one continuous process.

Key Design Features:

• ✔️ Optimized Strip Layout: Reduced material waste by 15%

• ✔️ Precision Punch and Die Sets: Ensured tight tolerances for every cycle

• ✔️ Durable Tool Materials: Designed for high-volume, long-term production

We also simulated the entire process using CAD/CAM and FEA tools to validate the design before manufacturing.

The Results:

✅ 30% Faster Production Cycle
✅ 15% Material Savings
✅ 99.8% Part Consistency Across Batches
✅ Significant Reduction in Handling and Labor

The new progressive tool allowed the client to consolidate their multi-step process into a single press stroke, dramatically improving their production efficiency and reducing costs.

Client Feedback:

“The progressive tool from INDUSTRY TOOLING transformed our production line. We now produce more parts in less time, with virtually zero defects.”
— Production Manager, Tier 1 Automotive Supplier