We’re thrilled by the high level of interest and the questions that enriched the discussion, allowing for a direct exchange on real cases and daily challenges in the industry. A special thanks to our internal experts: Matteo Margiri, Andrea Panvini, Ermo Fusè, Matteo Colombo, and Marco Scaramuccia, for offering concrete insights drawn from their experience at Bruschi foundries, making the webinar even more relevant and practical.

Stay tuned for future in-depth events and updates on industry developments.

Thank you once again for your participation and interest!

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The sustainability analysis conducted together with Siemens AG highlighted the tangible benefits of adopting eco-friendly energy solutions. By purchasing 100% green energy, Bruschi has fully achieved its primary goal of reducing its carbon footprint and improving operational efficiency, while significantly cutting CO2 emissions and reducing long-term operating costs.

In conclusion, the integration of renewable energy in factories represents not only an opportunity to reduce environmental impact but also a strategic investment for the future. With Siemens AG’ guidance, companies can embark on a path of sustainability that not only enhances their image but also contributes to building a greener and more responsible world.

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The circular economy of zinc alloys

The eco-sustainable approach to zinc alloy die casting offers several distinctive benefits. Firstly, the process is based on the efficient use of resources, as zinc is an abundant material on Earth and can be recycled repeatedly without losing its mechanical properties. These characteristics make it possible to reduce the extraction of natural resources and to limit the environmental impact associated with the extraction itself. Furthermore, its ability to be melted down and reused repeatedly without ever losing its mechanical properties makes it an ideal product for the circular economy.

The circular economy is an economic system based on the reduction, reuse, recycling, and restoration of resources. Instead of considering products as objects to be used and discarded, the goal of the circular economy is to create a continuous cycle in which materials and resources retain their value for as long as possible over time.

The properties of zinc alloys obtained by die casting are perfectly suited to the needs of the circular economy since they can be remelted and reused repeatedly, returning to being a raw element ready for new processing. For this reason, it is correct to say that zinc is a material that is reused during its life cycle and not “consumed” as can happen with other materials, which, after each recycling and reuse, tend to lose part of their mechanical properties or chemicals arriving at an “exhaustion” of the material and turning into an unusable waste.

It is also recognized that metal recycling plays a key role in ensuring the availability of resources necessary to maintain and expand the technologies and infrastructure of the future.

The reduced environmental impact of zinc alloys

Zinc die-casting is a much more sustainable process, especially from the point of view of energy consumption, compared to other metal die-casting processes such as aluminum for example. This fact translates into lower greenhouse gas emissions (GHG – Greenhouse Gas) and a reduction in the overall carbon footprint (CF – Carbon Footprint). Furthermore, the die casting of zinc alloys requires less energy to reach the melting temperature than other metals, contributing to further energy savings.

The results of the life cycle assessments (LCA) of zinc alloy die-cast products confirm the low environmental impact. The Life Cycle Assessment (LCA) is, in fact, a methodology used to quantify the ecological effects of a product or service throughout its life cycle: from production to the end of its useful life in which it effectively becomes waste and is no longer usable. This methodology assesses environmental impacts regarding greenhouse gas emissions, energy consumption, water and natural resources use, waste generation, and other environmental factors.

CO2 emissions and other categories that stand in the way of CO2 neutrality. The CO2-neutral concept “avoid – reduce – compensate” can be followed, i.e.:

• Avoid emissions at the outset, both for material extraction and processing.
• Reduce emissions, where possible, during production processes by implementing measures to ensure greater energy efficiency and self-sufficiency.
• Offset the CO2 emitted through projects or certificates that can offset unavoidable emissions.

Conclusion

In conclusion, the eco-sustainable die casting of zinc alloys offers an advanced and responsible approach to production. Thanks to the combination of production efficiency, recyclable materials, and reduced environmental footprint, this technology is aimed at companies that want to achieve environmentally friendly results without compromising functionality. Zinc alloys can replace less sustainable materials by improving energy efficiency and dramatically reducing overall environmental impact.

Furthermore, in our article on the Automation of the die-casting production process, we explore the benefits in economic and, above all, environmental terms of a production process converted from manual to automated. By analyzing a specific case study, you will discover how the die-casting industry is adopting new advanced processes to achieve ever more ambitious quality and environmental sustainability objectives.

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Characteristics of zamak

Zamak is an alloy composed of zinc, aluminum, magnesium and copper. According to the different percentages of these components the alloy has variable characteristics and can be used for the manufacturing of products for different market sectors. For an in-depth look at different types of zamak and their features, read the article ZAMAK molding in hot chamber die casting: chemical composition.

The characteristics of zamak that are particularly beneficial for the production of components for electronic products are:

Electromagnetic shielding

Zamak has good shielding properties with reference to Electromagnetic Interference (EMI). Therefore, it is especially suitable for the production of housings for electromagnetic cards because it is a product that requires a reduction of interferences

Heat dissipation

The properties of heat dissipation of zamak are similar, if not higher, to those of other materials. In this case, what makes zamak products competitive is the manufacturing cost of the product, the lifespan of the mold and the possibility to achieve products that do not need relevant secondary mechanical operations. For further information about this property of zamak, we suggest this case study: Zinc Heatsink Case Study: Loewe TV Heatsink.

Thin wall thickness and reduced dimensions

Zamak fluidity allows the achievement of a very thin wall thickness and of an extremely high level of detail in components of reduced dimensions. This is particularly important in the case of electronic products, which usually are characterized by very small dimensions and by a great number of details.

Stiffness and anti-vibration properties

These properties of zamak are especially relevant in case of electronic products employed in critical environments. In the industrial field, for example, electronic connections of some kinds of machine tools could be exposed to mechanical stress or vibration. It is evident that in cases like the one just described, zamak offers a protection and a vibration damping capacity that plastic could not offer.

To discover something more about chemical, physical and mechanical characteristics of zamak read the Zinc Association Engineering in Zinc, Today’s Answer, which contains very detailed information on these subjects.

Zamak components for electronic products: characteristics and competitive advantages

Let’s now analyze some zamak components for electronic products to examine their characteristics and competitive advantages.

Hard disk case

In this hard disk case we can observe how zamak properties contribute to the functionality of the product in several ways. Indeed, the case is anti-vibration and this allows the hard disk to work in stable conditions. Furthermore, as you can see in the picture, the product has both very small particulars and thin thickness. Specifically, directly during casting phase thanks to zamak it has been possible to realize the honeycomb grid that allows heat dissipation in the server through air circulation. With other materials the grid could have been achieved only through secondary operations, such as shearing, with unavoidable consequences in terms of timing and costs.

Housing for steering wheel lock

This housing hosts the electronic card of the steering wheel lock. In this case it is the properties of electromagnetic shielding and stiffness of zamak to make the product competitive compared with other similar products manufactured with other materials. As a matter of fact, the shielding allows the electronic card to function in optimal conditions without being subjected to the interference of near electromagnetic fields. Then, for this particular product, stiffness makes zamak especially competitive compared to plastic. Often when plastic housings are installed electronic cards tend to bend, whereas  the stiffness of zamak leads to a higher protection, thus extending its lifespan.

Device for checking, counting and separating banknotes

As far as this product is concerned, zamak has replaced stainless steel, thus cutting production costs and the need for mechanical operations and finishing. This has been made possible by the properties of zamak and especially by the capacity of the alloy to reach thin wall thickness and a high degree of detail. In this way the customer has obtained a product that does not need to be assembled, manufactured with molds with a long lifespan, which need little maintenance and with scrap rates close to zero.

Housing for corporate network connectors

The housing for corporate network connectors is illustrative of the properties of shielding, stiffness and resistance of zamak. For these kinds of products, shielding properties of zamak allow freedom to the electronic designer, who can mitigate the drawbacks linked to the electromagnetic waves without special precautions, but only through the choice of the most suitable material. Stiffness and resistance of the material make the use of the component suitable for particularly critical environments, such as production departments of a plant.

Conclusions

With this brief overview on zamak components for electronic products we have analyzed how some properties of zinc alloys allow the achievement of competitive and effective products. However, these are not the only components for the electronic industry that can be manufactured in zamak. For a more comprehensive overview visit our website www.bruschitech.com in the Services page.

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Cost reduction strategies in zinc die casting

Cost reduction in zinc die casting can be implemented in different ways. In fact, zinc is a versatile metal that, if manufactured with the right technologies, allows saving not only in absolute terms, because it allows the die caster to save the time, energy and raw material that are required in the process, but also compared to other metals.

In the production of die-casts it is possible to implement cost reduction by:

•  Choosing zinc instead of other metals or other metal alloys
•  Optimizing the productive process
• Designing processes and components together with the customer through co-design methods

  When it comes to save during die casting process it is also important to choose the right die caster, if you want to learn more on the matter read How companies can save while selecting the die caster.

Advantages of zinc: chemical and physical qualities and characteristics, melting temperature, circular economy

Zinc alloys usually employed in the die casting process have some properties that make them competitive if compared to other metals. These are chemical-physical properties that allow the reduction of costs related to productive processes and to the subsequent stages, such as, for example, those of disposal and recycling. Let’s analyze these characteristics in detail.

Chemical-physical qualities and properties

In the die casting process different zinc alloys are employed. The most common of those alloys are Alloy 2, 3 and 5, and they are chosen for the production of different components depending on their chemical-physical properties. In fact, according to the percentage and the relative values of the metals that are contained in them, the alloys have different characteristics that make them more or less appropriate to realize different typologies of products. For example, if the component is a safety product the alloy that guarantees the greatest resistance to wear, corrosion and pressure, yield strength and dimensional accuracy is to be chosen. In case of a technical component, for which it is often important to achieve details and thin ribs, the Zamak to be preferred will be the most fluid because it will be capable of spilling over the mold in the most uniform way. In this way it will be possible to obtain thin walls thickness that is essential to guarantee the functionality of products. Finally, for aesthetical products Zamak alloys able to ensure the best surface quality and the best performance if subject to subsequent processing and finishing, are to be preferred. Therefore it is very important to know the chemical-physical characteristics of the different zinc alloys in order to choose the most suitable for the production of a specific component. Only in this way, in fact, it is possible to make a winning choice and obtain, with reduced scrap rates, quality die casts that need a reduced number of finishing and further processing.

If you want to discover more about different zinc alloys and how to take advantage of their specific characteristics read the articles The best zinc alloys for hot chamber die casting and Zamak molding in hot chamber die casting: chemical composition.
To deepen your knowledge about the advantages of zinc in comparison to other metals read The importance of zinc die casting in automotive industry and Coating, plating and other kind of surface treatments.

Melting temperature

One chemical-physical property that has a great impact in terms of cost reduction is the melting temperature of Zamak. The melting point of Zamak, in fact, is low and this allows hot chamber die casting. Differently from aluminum, which has a higher melting point and that is cold chamber die cast, Zamak allows energy saving provided by the different technological process used to melt the material. There are further advantages related to time that are connected to hot chamber die casting: hot chamber die casting is a faster process than cold chamber die casting and, as a consequence, it has an increased productivity. Another saving factor related to melting temperature is that the mold, subjected to lower temperatures, is affected by less wear and, for this reason, has a longer lifetime, with beneficial effects especially in large scale production.

Circular economy

In this brief review of the qualities of zinc in comparison to other metals one last property has to be mentioned: recyclability. Zinc, in fact, fits in circular economy processes and therefore meets the recent trends toward environmental sustainability. Zinc recyclability is not only an advantage for the final consumer, who can recycle products and appliances, but it is also an important factor of cost reduction for the die caster. In fact, if the agreements with customer allows it, zinc can be re-melted and, in controlled percentages, it can be reintroduced in the productive process with evident consequences in terms of reduction of scrap rate and of optimization of the productive processes.

If you wish to learn more about the possibility of recycling Zamak click here.
If you look for insights on zinc circular economy we suggest you to read Zinc life cycle: how it contributes to circular economy.

Productive process optimization

In regards to cost reduction in die casting not only the properties of zinc are important but also the productive process with which the metal is manufactured. Die casting techniques and machineries have to be up to date with technological development in order to be efficient, for this reason constant research and innovation are necessary. It is also important to have effective supply chain and logistic managment, if you want to learn more click here.

For a general overview about these topics we suggest you to read the article Production process improvement in the die casting industry. If you wanto to deepen your knowledge on the  analysis necessary to optimize the productive process read the article How die casting companies can help you save time and budget.

Automation and cycle time

An important step to achieve cost reduction is, for example, the introduction of automation in the productive process. In fact, automation makes the system more efficient by diminishing the percentage of scrap and allowing the operators to deal with activities with a greater added value.

Moreover, the acquisition of automation is closely related to the capability of updating and implementing the productive machineries. Thanks to the purchase of new machineries activities that used to be manual become automatic with a resulting diminishing in lead time, cycle time and scrap rate and a noticeable increase in productivity. Cycle time, in particular, is very important in relation to cost reduction strategies: in fact diminishing cycle time means increasing OEE, the productive performance index of a plant, and, consequently, the production. In the specific field of hot chamber die casting the reduction of cycle time represents a further saving opportunity because, in a reduced cycle time, the thermal power that the melted material provides to the mold is increased with a resulting decrease of cold fronts and related defects.

If you want to learn more about automation and its importance for the production process read How automation helps improving the production process; if you want to discover more about cycle time and its optimization we suggest you to read How die casting cycle time optimization can help to reduce costs.

Simulation

Another strategy to optimize the productive process is to use simulation software that allow designers to forecast what is going to happen during the die casting process. Simulation is a useful instrument to prevent problems, errors and defects during the production of the die casts and it is, moreover, a fundamental aid during design, prototyping and testing phases.

You can find a study about the advantages of simulation in zinc die casting clicking here.

Quality certifications

A guarantee of optimization of the productive process and of the subsequent cost reduction is the achievement of quality certifications. Smeta 4 Pillars, for example, is a certification of qualitative standards, environmental management, company integrity, health and safety with a noticeable impact in terms of cost reduction. In fact, Smeta 4 Pillars through the sharing of standardized approaches improves and aligns the productive process safeguarding brand reputation and guaranteeing an ethical supply chain.

Co-design

Co-design consists in a series of activities aimed at increasing the value of the product and at improving it in terms of quality and efficiency. Often these activities do not result in an increase in production costs but, on the contrary, they result in a decrease in costs. Through co-design, if already implemented during designing phase, it is possible to agree with the customer on weight reduction, elimination of secondary operations, optimization of the mold and a number of other actions that directly lead to a noticeable cost reduction. Obtaining a drawing that is already optimized for mass production allows the customer to have a final product that is in line with expectations and with less risks and scraps. As a further assurance of cost reduction, already during co-design phase, it is possible to undertake a VA/VE value analysis and to optimize the process through the DFM. VA/VE value analysis is a method of problem solving that allows the effective identification of unnecessary costs making it possible to reduce them. DFM, Design for Manufacturability, is a feasibility study in which the design of the product is evaluated and in which adjustments, special treatments and structural modifications are proposed in order to make the optimization of the production possible.

For a deeper insight on co-design we suggest you to read the article Product design for die casting, if you want to deepen your knowledge on VA/VE read The zinc die caster impact on production costs reduction. 

The methods to implement cost reduction in zinc die casting and to optimize processes and products do not end here. However, by reading this article you should have had evidence of some important benefits of cost reduction.

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Minimum wall thickness

The characteristic of zinc alloys that allows the achievement of a particularly thin wall thickness is the capability of filling small cavities. Thanks to this feature zinc alloys can reach an average minimum thickness of 0,4 mm: an extremely low value, especially if compared to the average aluminum rate, as shown in the table below:

Thin wall thickness obtained with die casting process is determined by different factors, such as the shape of the component and the extension of its surface. Another factor that influences the thickness of the wall is the distance between the thin walls and injection point: lower the distance, thinner the wall.

Thanks to its filling capability and the possibility of obtaining a high rate of precision, zinc alloys allow the production of components that do not need further mechanical operations. Indeed, right after die casting process they already have precise finishing and thin wall thickness.

The advantages of thin wall thickness

So, why is the capability of obtaining thin wall thickness an added value when producing a die cast?

Below a list of the main advantages that result from thin walls both in terms of features of the product and cost and energetic savings:

1. Weight reduction of the component
2. Size reduction of the component
3. Possibility to obtain components with a high degree of detail
4. Resistance
5. Energy saving
6. Cost saving

1. Weight reduction of the component

Achieving a weight reduction of the component while maintaining its functionality is one of the main advantages of thin wall thickness in zinc die casting. As a matter of fact in specific sectors, for example in the automotive industry, to have the chance of reducing the weight of a component and at the same time to preserve its functionality represents an important benefit in terms of efficiency. This is particularly true for some specific components, such as car handles and sunroofs.

Thanks to the design freedom offered by zinc alloys the die casting supplier can analyze, starting from the original drawing, the shape of the product and collaborate with the customer for the identification of the areas of the product that can undergo a thickness reduction without compromising the functionality of the component but, on the contrary, enhancing it.

The cooperation between customer and supplier, a service defined co-design, can therefore lead to the development of innovative solutions able to increase product performance while, at the same time, generate a cost reduction provided by an inferior amount of raw material that has been used.

The percentage of weight reduction of the component is clearly variable, because it depends on the characteristics of every single product. Starting from the original project until reaching the new project redefined together with the customer, in some cases it is possible to achieve a weight reduction up to 50%. It is a percentage of considerable importance that is unlike to be reached with other materials.

For further information about weight reduction in die casting, read this post: Weight reduction: lightweight as a benefit of co-design

2. Size reduction of the component

Weight reduction is not the only important factor for the functionality of a product, indeed also dimension is very relevant, especially for those devices whose technological development require increasingly reduced dimensions.

Through the process of co-design the die casting supplier, together with the customer, studies solutions aimed at achieving this optimization by identifying the areas of the shape of the product that can undergo a wall thickness reduction.

In particular, products with a housing function, such as electronic connectors, need thin wall thickness in order to be more functional. Indeed these products contain in their inside other components and, in order to avoid space and obstacles issues, it is necessary that their walls are as thin as possible. Moreover, for this kind of products, zinc alloys are a winning choice because beyond the capability of reaching thin wall thickness they also maintain unaltered the electromagnetic shielding properties, which are extremely important for electronic industry.

Still as regards products with a housing function, for example cases for windows and doors handles, which do not have a primary mechanical function, zinc alloy are ideal because it allows the achievement of thin walls also with complex and unusual shapes. Usually this type of products is produced with metal sheet, a highly elastic material that, if treated with the deep drawing process, can reach an extremely thin thickness. However deep drawn metal sheet, unlike zinc alloys, does not offer design freedom because it does not allow the achievement of the complex geometries that can be obtained through die casting process.

If you want to have a look at a housing product with thin walls that, thanks to co-design, has achieved a size reduction and thinner walls, with a great saving for the customer, you can watch this video

3. Possibility to obtain components with a high degree of detail

As already said, with zinc die casting it is possible to obtain extremely precise products with complex shapes. Those shapes are often characterized by a great number of very small details, especially with products such as connectors and heat sinks that present a complex rib design.

Thanks to the reduction of wall thickness obtained with the die casting process those tiny details can be realized with extreme precision, thus assuring dimensional accuracy and efficiency of the product. Furthermore, the achievement of thin wall thickness in this kind of products adds value because it confers elasticity and therefore facilitates assembling and blocking systems.

Tests performed on thin wall zinc alloys samples have indeed highlighted results that are comparable with those of plastic materials: in particular, the elastic modulus of zinc alloys samples proved to be superior to that of nylon 6.

4. Resistance

Thin wall thickness does not mean inferior resistance. On the opposite, thinner walls have a crystalline structure that is more subtle than the one of components with thicker walls. This structure has superior mechanical properties, so the product is characterized by a high degree of resistance.

During the die casting process, the rapid superficial cooling generates what is generally defined “skin”, a superficial layer of 0.2-0.3 mm with a thin structure. The results of fatigue tests performed on zinc alloys diecastings with thin walls showed the advantage resulting from the presence of the “skin”. Indeed, in a diecasting with thin wall thickness the crystalline microstructure is greater in percentage terms and this gives greater resistance to the component.

Furthermore, other tests on thin wall thickness diecastings, pointed out fatigue strength values remarkably superior to those of zinc alloys treated with other technologies.

6. Energy saving

The achievement of thin wall thickness and the production of components with this feature allow the reduction of the quantity of energy used during the production process. Thin wall thickness indeed entail a reduction of the amount of raw material to be used and this, in the first place, translates into an inferior quantity of raw material to be re-casted.

In addition, components with thin walls have reduced cooling times and this generates not only an energy saving related to the functioning of the die casting machines, but also an increased energy efficiency of the whole process and a consequent reduction of production times.

7. Cost saving

The use of a lesser amount of raw material, the increased energy efficiency, the speeding-up of the productive process and the reduction of weight and dimensions, with the resulting transport costs saving, are all factors that lead to a considerable reduction of production costs. The cost saving resulting from the production of components with thin walls thus translates into an important benefit not only for the supplier, but also for the customer.

Zinc die casting is therefore a competitive technology from an economic point of view, it indeed allows the achievement of thin wall thickness and it is the ideal choice for the production of light and resistant components, characterized by complex and detailed shapes.

For an overview on components produced in Bruschi, including products with thin wall thickness, click here

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Productivity enhancement represents, indeed, an advantage both for the supplier and the client: on the one hand the supplier benefits from costs savings, while on the other hand the client can rely on a partner that offers quality performances in short times. Bruschi has always considered this subject a core aspect, as a matter of fact through the years Bruschi has taken several measures in order to achieve an ever-increasing process improvement.

How to reach process improvement

Process improvement can be developed through a well-defined action plan, which takes into consideration the complexity of elements that characterizes the production department. Production is indeed composed not only of machinery, but also of product design, technologies, operators and planning activities, to mention some of the most important components of this structured system. To improve the production process it is therefore crucial to have a comprehensive view of all these elements, in order to implement a strategy that is functional on multiple aspects.

As a consequence, the first step to take is the setting of the tools and of the adjustment actions that can impact on the improvement of the different stages of the production. In Bruschi the process improvement plan is composed of four central elements:

1. Automation

2. Simulation

3. Scrap reduction

4. Cycle time

1. Automation

The introduction in a production system of automated machinery equipped with state-of-the-art technologies generates relevant benefits in terms of reduced lead time, costs reduction and achievement of quality standards requested by clients. The replacement of workforce with automated systems allows, indeed, to obtain a faster process, consequently enhancing the whole lead time. In addition to that, automation leads to a reduced likelihood of error compared to manual operations. This translates into a relevant production costs reduction, which is further increased thanks to energy and material saving that automation generates. The introduction of automated machinery in the production department produces another significant advantage that allows quality control improvement, too. As a matter of fact, operators that previously dealt with manual operations on the component thanks to automation can take responsibility for other activities with a higher added-value, such as quality control.

A process improvement project of a specific component, for a client of the sector of small appliances, has obtained excellent results in terms of increased productivity and decrease of manual activities of operators. Process improvement project has been developed in order to solve a situation of misalignment between production capacity and client’s demand. Through the introduction of automated systems this gap has been narrowed, thus achieving an optimized cycle time. After several studies and researches it has been possible to apply some changes to the process, which have brought to significant benefits: an increase of 33% of production capacity and a decrease of -95% of manual activities made by operators.

For more detailed information on automation consult the post below:

• How automation helps improving the production process
• The Importance Of Automation Optimize The Production Time

2. Simulation

Simulation of the die casting process represents another essential element that impacts on process improvement: with simulation software engineers can indeed foresee material reactions inside the mold. This process is feasible thanks to a thermos-fluid dynamic analysis of the mold, known as CFD simulation (Computational Fluid Dynamics), which allows the engineer to detect potential defects, such as cold laps and hot spots, on the die cast. The simulation stage proves especially helpful to obtain an optimized mold design before starting with the production process. During this stage it is indeed possible to select the best mold design parameters to apply, so that potential defects on the piece are previously detected and, consequently, production costs and further mechanical operations are reduced.

If you are interested in simulation, here are additional posts on this topic:

• The Benefits Of Simulation In Die Casting Design
• Die Casting Simulation For Shrinkage Porosity Prediction
• How To Use Die Casting Simulation For Cost Reduction
• Hpdc Simulation For Die Casting Process Optimization
• Die Casting Simulation A Casting Process Optimization
• Hpdc Simulation Benefits For Die Casting
• Simulation For Hpdc Surface Aesthetical Quality In Automotive Case Study
• Simulation For Hpdc Shrinkage Porosity Case Study
• Simulation For Hpdc Die Maintenance And Optimization Of Set Up

3. Scrap reduction

Scrap reduction can be achieved through an accurate planning of the whole production process of a component. First of all it is necessary to carry out a product and process analysis that focuses on the causes of scrap. To identify these causes engineers must use simulation software to foresee every stage of the production, from design to finishing operations. Once again simulation proves to be an indispensable tool for zinc die casting process improvement, because it allows engineers to avoid defects and to check technical properties before starting with the component production, thus producing a consistent costs and lead time reduction. Once scrap causes have been figured out it is possible to proceed to the outlining of potential solutions to apply, identifying the most relevant steps in the production process and constantly checking them.

To know more about scrap reduction, here are extra posts on the topic:

• How To Reduce Scrap In Die Casting Process
• Simulation For HPDC Scrap Reduction Case Study

4. Cycle time

The expression cycle time defines the period of time required to produce a product. Cycle time represents a central variable in the production of a component because a reduced cycle time results in a reduced lead time, which is the period of time needed to accomplish a customer’s request in terms of supply. An optimized lead time generates an increase in the client’s satisfaction, because it allows the supplier to meet deadlines and standards demanded by the client. As a consequence, in order to guarantee a rapid and efficient service, cycle and lead time have to be enhanced to the maximum extent possible. Cycle time can be shortened paying attention to different aspects of the production process, especially to simulation stage and to technological systems of the production department. First of all, as already mentioned, it is important to simulate production and defining the best process parameters to apply for the production process. In this way potential defects will be avoided from the very beginning and, consequently, it will be possible to eliminate further mechanical operations. Another core element for cycle time shortening is the technological system of the foundry, whose technological innovation level can generate relevant time reduction during the production process. As a matter of fact, automated machines lead to optimized cycle times and to more accurate operations, discriminating factors for the achieving of performances requested by customers. Furthermore, periodical checks on machinery help understanding how cycle time can be further improved.

Check the posts below to learn more about cycle time:

• Process Optimization For Die Casting Cycle Time Reduction
• How Die Casting Cycle Time Optimization Can Help To Reduce Costs

Why process improvement is crucial for a business

Process improvement is a crucial element in the management of a business because it leads to production costs reduction and faster productive processes. With the aim of reaching these benefits it is therefore necessary to introduce automated technology and simulation software in the production process, and to optimize scrap reduction and cycle time. With the outlining of a precise process improvement plan lead time can be shortened and, as a result, client’s satisfaction will be increased.

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Supplier’s impact on VA/VE

An increasingly important part of procurement strategy is to involve suppliers and strengthen collaboration in product development, cost reduction and enhancement activities.

Joint Value Analysis/Value Engineering is one of the best ways to pursue long-term goals and to establish good business relationships with suppliers: trust and open-share of information and ideas are the basis of commercial collaborations.

Informing and involving suppliers in VA/VE activities can help to clarify the process definition and to encourage alternative proposals, resulting in more competitive price and/or better product.

The benefits of cost saving, process improvement, and transparent communication are shared between suppliers and customers. The former is able to determine a calculated cost reduction, to show potential quality improvement or scrap reduction with supporting data; the latter can benefit from open communication, cost reduction and/or better quality.

A supplier involved in VA/VE analysis can make proposals for:

Component design changes

These modifications are usually proposed by a dedicated engineering department and studied using simulation and analysis tools to support customers since the beginning of a project. These changes can help to reduce scrap production and component’s weight, to improve structural and mechanical qualities of the piece and to prevent future issues. All these activities lead to improved functionality of the components, therefore increasing their value.

These changes may regard:

• Materials or specifications
• Dimension or tolerances
• Components substitutions

Manufacturing or assembly process changes

With simulation software, it is possible to try out a number of process variations to obtain the best optimization possible without wasting any material. These tools make it easier to spot critical points and to apply correction where needed, especially in those situations in which the root cause may not be clear just by analyzing the casted component.

Modifying the process and the technologies involved before creating a prototype or casting a trial batch grants a great saving in terms of material used and less machine time wasted. In other words, during a VA/VE analysis the simulation of manufacturing process can increase the value of the product by reducing costs.

Some of these changes may regard:

• Tests reduction
• New process technology
• Part reliability

Logistics

A better communication between parts is crucial to achieve a functional supplier network. Sometimes the supplier can take care of shipments costs, adjust schedules to meet urgent needs, or even arrange shipments to make the most FLT (Full Load Transport) possible, thus cutting costs.

Some area of Logistics in which suppliers can help are:

• Reduced freight costs
• Packaging improvements
• Inventory management

Once the customer’s procurement receives proposals, a team composed of experts from different departments will review them to determine feasibility and eventually merge the new obtained result in their procurement strategy.

How a Die Caster can support VA/VE activities

Product engineers are always trying to reduce production and material costs, maintaining at the same time the quality of products. Value Analysis / Value Engineering is fundamental to reach that goal.

We can classify manufacturing costs into:

• Raw materials
• Labor
• Process

Let’s see each point in details.

Raw materials

As every procurement strategy specialist knows, raw materials prices depend on a wide range of factors, from widespread availability to fluctuation of the market.

Sometimes a change in material can be necessary to keep the production costs under control, or to cut unnecessary costs and increase the revenue for a product. For example, choosing to use zinc instead of aluminum, stainless steel or any other material could help to cut costs.

But even when using the same material, there may be differences in price and quality: for example, zinc alloys come in wide varieties and in different price sets. Choosing the right kind of alloy is important not only for the final product, but it could also help saving. To be sure to choose the best material both in terms of technical quality and cost-wise,  it is advisable to ask your supplier for advices by involving its team in your VA/VE analysis.

Labor

The manufacturing process necessarily includes labor costs: some of these may be avoided by speeding up the operations, for example through the use of automations, or by carefully designing components to reduce after-production operations and make the assembly easier.

Process

Process requirements can vary greatly depending on the industry. When considering die casting industry, the typical cycle time is composed of the following phases:

• Injection time;
• Die casting technical time;
• Mold shifting/lubrication time;
• Control time;

There are different ways of optimizing these processes, but in many cases automations and IT can help. Some programs can simulate the entire production cycle: based on data acquired from the analysis, it is possible to anticipate any issues and minimize risks, finding the most suitable solution for each project.

To conclude, we have seen how involving die casting suppliers in a jointed VA/VE analysis can help improving different phases of the production: from product design to process optimization, almost every area can benefit from an expert suggestion. Therefore, contacting suppliers while developing a new procurement strategy could increase the value of a product, either by improving component’s functionality or by reducing production costs.

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VA/VE Analysis History

In 1961, in his book “Techniques of Value Analysis and Engineering”, American engineer Lawrence D. Miles stated:

 “Value analysis is a problem-solving system implemented by the use of a specific set of techniques, a body of knowledge, and a group of learned skills. It is an organized creative approach whose purpose is the efficient identification of unnecessary costs, i.e. cost that provides neither quality nor use nor tool life nor appearance nor customer features.”

The term Value Analysis / Value Engineering originated in the early days of technique development and its first approach was to increase value, rather than to reduce costs. Therefore there was a need to analyze value.

Lawrence D. Miles continues:

“Value analysis approaches may assist all branches of an enterprise-engineering – manufacturing, procurement, marketing, and management – by securing better answers to their specific problems in supplying what the customer wants at lower production costs. Quite commonly, 15 to 25 per cent and often more of manufacturing costs can be made unnecessary without any reduction in customer values by the use of this problem-solving system in significant decisional areas.”

VA/VE is an extremely powerful approach with over a century of worldwide application and it can be applied to any cost generating areas with equal success.

Il VA/VE è un approccio estremamente efficace con oltre un secolo di applicazioni in tutto il mondo e può essere applicato ad ogni area che genera costi con lo stesso successo.

Value Analysis / Value Engineering Definitions

Value Analysis – VA

What is value?

Different customers will answer to that question in different ways. The value of a product can be the performance of its functions or its aesthetic beauty, when applicable and needed. As a general statement high level performances, capabilities, emotional appeal, style, all compared to cost is commonly what we consider as value.

Therefore Value = Function / Cost

Value Analysis is a standardized, multi-skilled team approach which aims at identifying the lowest cost way and ensuring the highest worth to accomplish the functions of a product, process or service. Value analysis means to assess product functions and value-to-cost ratios, and to find opportunities for costs reduction.

Value Engineering – VE

As we said above, Value Analysis is the application of several techniques to identify the functions of a product (or service) and provide them at the lowest cost.

Value Engineering refers instead to the design stage. This approach is generally used for new products, therefore the same principles and techniques to pre-manufacturing stages such as concept development, design and prototyping are applied.

To sum up, VA / VE is an orderly and systemic method to increase the value of an item, which can be a product, system, process, procedure, plan, machine, equipment , tool, service or working method. Function analysis is part of VA as its purpose is to identify product functions compared to cost and price; design and construction assessment is done through VE with the goal of  eliminating elements which are not contributing to function.

Product’s function should not be conceived solely as its application and practical uses: it can also include aesthetic factors, or the union of the two following dictates of functional beauty philosophy: this theory is based on the coexistence of aesthetics and performance. What matters the most in drafting a VA / VE is that the function is clearly defined, so that it can be analyzed in detail and sub-segmented to make the analysis easier.

If you are interested in functional beauty, Bruschi is going to give a lecture on the topic: click here to learn more.

In VA/VE the function of a product or service, defined by customers to meet their requirements, is identified, the monetary value for that function is established, the specified performance and requested reliability provided at the lowest Iife-cycle cost.

Following a VA/VE approach it is possible to increase customer satisfaction and add value to the investment.

Even the best and most innovative designs can age and become uncompetitive: in these cases VA/VE can support both customers and suppliers in finding and optimizing any value mismatches in products, components, processes, projects or low performing functions.

A correct segregation between necessary and unnecessary functions of products leads to a creative development of alternative ways of accomplishing them – as requested by customers – at lower cost.

VA/VE enables a company to highlight areas that need to be analyzed and improved, with a standardized method which generates ideas and alternatives, considerably increasing the value of goods and services.

A project completed with VA/VE technology is more successful and efficient than a project developed without that approach, because goals and requirements are pursued in a customer centric way. VA/VE is almost unlimited in identifying area of potential savings, as it can be used to reach quality, improve efficiency and reduce risks, in a cost saving way.

VA/VE Approach & Main Steps

According to the principles of “Techniques of Value Analysis Engineering” there are different phases of VA/VE:

• Exhaustive accumulation of information and identification and improvement of assumptions.

• Penetrating analysis. What senses of direction does this informative provide us with? What specific problems will, when solved, bring important cost benefits?

• Creative mental activity, in which all judgement is temporarily deferred to form the roots of a variety of different solutions to each of the specific problems developed in the preceding analysis.

• Judgment-type mental activity, in which what results from creative thought is searched for ideas roots to minimize disadvantages and maximize advantages sufficiently to meet the need for cost and/or operation improvement.

During the information phase, the project and its requirements are analyzed, and then the function analysis studies the possible room for improvement. In the creative stage ideas to increase performances are developed: from the resulting list of ideas only a short set is evaluated in order to find the ones with best potential to reach the goal. The following step is development of alternatives and their presentation to decision makers and, eventually, implementation.

VA/VE tools are extremely powerful and fundamental to reach objectives such as decreasing costs, improving quality and shortening time-to-market.

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