VA Example
Head inserts
| Material | A6061 |
| Quantity | 100,000 parts/month |
| Existing method | Aluminum die casting |
| VA method | Fully cold heading process of whirl stop parts |
| Results | Approximately 30% of cost reduction |
| Key-point | Forming of the whirl stop parts fully manufactured by cold heading process |
Shaft
| Material | SWCH10R |
| Quantity | 50,000 parts/month |
| Existing method | Double head + Milling + Deburring |
| VA method | Manufactured fully by cold heading process |
| Results | Approximately 10% of cost reduction ＋ Production volume improved (1,000 parts/day ⇒ 25,000 parts/day) |
| Key-point | Forming the slot by parts former in order to manufacture fully by cold heading process. |
Limiter gear
| Material | SWCH12R |
| Quantity | 30,000 parts/month |
| Existing method | Manufactured by Beric die-cast method |
| VA method | Changed to Forging method. |
| Key-point | Increased the strength of peripheral gear part by changing the manufacturing process to forging. |
Weld nut
| Material | SWCH10R |
| Quantity | 50,000 parts/month |
| Existing method | Manufactured with Nut former (5 stages) |
| VA method | Manufactured by cold heading process with 2D3B |
| Results | Approximately 20% of manufacturing cost reduction. |
| Key-point | Achieved a manufacturing method at low rank facilities to reduce Processing fees |
Work flow from consultation to delivery
SANKYO staff analyses the problem from various angles and provide with value adding solutions.
