[Technical Case] 47% Cost Reduction through Method Change

Experience in the electric power industry! Introduction of a case that achieved a 47% cost reduction through the conversion of copper material processing methods.

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We would like to introduce a case where we achieved a 47% cost reduction by transitioning the copper material processing method. **Challenge: "High production costs"** A major power component manufacturer consulted us, stating that due to high costs associated with machining, they were considering switching to forging to reduce costs. Since the component needs to carry 180A of electricity, any burrs could pose a fire hazard, so "burr-free" was a requirement. **Solution** - We transitioned from machining to cold forging, achieving a spherical shape through plastic deformation. - We also accommodated the machining of two holes using pressing. - We achieved a total manufacturing cost reduction of 47%. **Actual Product** - **Consultant:** Major power component manufacturer - **Product Name:** Parts for transformer contacts (annual production of 1,000 units) - **Material:** Tough pitch copper - **Size:** For 180A (left: 60×40×12), for 90A (right: 51×20×6) For more details, please refer to our catalog or feel free to contact us.

Casting and metal decoration