The Impact of Process Substitution on Manufacturing Costs: A Comparative Analysis of Sheet Metal Forming versus Extruded Steel Cutting

Abstract

Sheet metal manufacturers continuously seek methods to enhance automation and reduce costs. This thesis explores process substitution and design standardization through a parameter-driven cost model and case studies applying Design for Manufacturability & Assembly (DFMA) principles. Specifically, it evaluates substituting conventional sheet metal components with extruded steel profiles and replacing manual press brake operations with automated tube laser cutting. The findings show that tube laser adoption across a broad range of channels can reduce costs by 49% to 79%, with a payback period of under two years, even in scenarios with fluctuating raw material prices. The study proposes strategies for maximizing tube laser utilization through product mix analysis, redesign for compatibility, and designing with tube laser as the primary method. A developed automation tool using clustering aids profile identification, though the study highlights the need for improved data management around C-channel dimensions to enhance process standardization. The investigation confirms that extruded steel can be a cost-effective alternative to large-scale channel products, providing solutions for industry transition through direct replacement, compatibility-focused redesign, or design guidelines optimized for extruded steel.