VAVE Cost Optimization: Forging Transition for Precision Clevis End Caps
RT Prime engineered a forged + CNC machining process that reduced unit cost, improved strength, and delivered long-term scalability for high-volume clevis end caps.
Client:
Category:
Manufacturing
Location:
Case Study: Process Optimization & VAVE – Forging Transition for Clevis End Caps Scaling production often exposes hidden opportunities for efficiency. When a customer approached RT Prime to review the manufacturing process for two precision-machined clevis end caps, our engineering team identified a pathway to reduce cost, improve strength, and streamline supply chain performance.
These components were originally produced as billet CNC-machined parts. RT Prime conducted a full Value Analysis / Value Engineering (VAVE) study, comparing the incumbent process to a forged + post-machining route through our Taiwan supply chain.
The result: a dramatic cost reduction after minimal production volumes, with improved material integrity and manufacturability.
Process Comparison & ROI Summary
Damping Tube Clevis End Cap
Costs
Original CNC: $22.01
Forging Tooling: $2,586
Forged + CNC: $8.10
Performance
Breakeven: 186 units
Savings After Breakeven: $13.91/part
Air Spring Tube Clevis End Cap
Costs
Original CNC: $29.23
Forging Tooling: $2,736
Forged + CNC: $12.39
Performance
Breakeven: 162 units
Savings After Breakeven: $16.84/part
The transition not only reduced unit cost but also provided:
Improved mechanical strength due to grain-flow alignment from forging
Lower material waste compared to billet machining
Greater long-term production stability
Predictable pricing for scaling demand RT Prime managed the complete process transformation — from tooling design and forging trials to post-CNC machining, validation, sampling, and logistics. Our global supply chain ensured a smooth transition without production interruptions.
Smarter manufacturing starts with better engineering decisions. RT Prime delivers the analysis, supply chain execution, and technical expertise to make those decisions possible.
