The component in question is linked to the safety of the vehicle’s driver and passengers. Due to its very nature, it requires a maximum tolerance of a few thousandths compared to the required weight of 6 grams. Such a tight tolerance level is challenging to be respected 100% in producing die-cast parts.

Bruschi’s R&D team and technical office took the lead in developing a pioneering project in the sector. Leveraging software development and cutting-edge technologies, they overcame the common limitations of die-casting production and met the customer’s demand.

Therefore, the mass production of zinc pieces smaller than a €1 coin was guaranteed, respecting the tolerance specifications provided by the customer.

Bruschi designed and implemented a fully automated production process to ensure precision and quality. This process involves the use of robots equipped with precision grippers capable of extracting the die-cast components from the molds. A camera placed on the machine allows the robot to independently verify the presence of all the pieces inside the mold, dismantle them, and place them on a precision scale for quality assurance.

Any pieces that do not meet weight standards activate a reject system.

This is an example of how technological progress and engineering skills make it possible to satisfy the market’s needs, overcoming production limits that only a constantly evolving company can overcome.

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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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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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