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As winner of numerous international awards, Bruschi Spa is known for its innovative approach in design and technology. We are glad to share our insights and experiences with the industry members.

How the right die casting supplier can help your company's VAVE

by Martina Fagnani December 19, 2016

A customer oriented company should focus on a co-design service that can help to cut costs. Manufacturing costs of products can be categorized into: raw materials, labor and process. In this regard product engineers are always trying to reduce production and material costs but also to maintain the quality of the product: value analysis and value engineering (VAVE) is really fundamental to reach this goal.


How the right die casting supplier can help your company's VAVE

Nowadays the business scenario is in constant demand. The focus is on innovation creating high performance products, reducing prices remaining always competitive and reaching the clients’ expectations. The choice of the right die casting supplier is crucial for companies, in fact the correct supplier is able to support its customer in every part of the process, helping the client to reach planning and project goals.

The right die casting supplier is able to help your company in your VAVE process.


What is VAVE?

VAVE is a systematic and organized procedural decision-making process. Is used to achieve the functions of a project, product, process or system in a cost saving way, always keeping in mind the importance of performance of the product.

VAVE is the process of reducing costs in a development project without compromising the design and its aim.

A project that is done with Value Engineering technology is more successful than other who do not because they can fix objectives and requirements in a customer centric way. We can say that this technology is almost unlimited in identifying area of potential savings.

It can be used to reach quality, improve efficiency, reduce risks always in a cost saving way.


VAVE approach

VAVE can reduce the total cost by 5-40%.

The main steps of VAVE are:

  • Information: Analyze the state of a project and its requirements
  • Function analysis: Understand the process function and analyze the areas of improvement
  • Creative: Generate ideas to make the product perform better
  • Evaluation: Fix a short list of ideas with the best potential to reach the goals
  • Development: Develop some alternative ideas
  • Implementation: Present some alternative values to decision makers

VAVE tools are fundamental to reach the desired objective, if it is applied correctly will be a powerful tool to decrease costs but at the same time improve quality and shorten time-to-market.


How to save with the right die casting supplier

In high pressure die casting is possible to save in three different ways:

  • Material
  • Assembly
  • Simulation


Is possible to save changing material: using zinc, instead of aluminium, stainless steel or other materials can be the answer in terms of saving.

Hereunder some case histories explaining how Bruschi has saved in terms of material for its clients:

Alcatel Lucent

Alcatel-Lucent needed a solution to cut the cost of components of its data center. Bruschi focused its attention over racks. Bruschi suggested to turn to zinc instead of aluminium: that means to reduce costs on material and machining process. The result was 20% cost saving.


Reichle & De-Massari wanted to improve their cable management and challenged Bruschi for ideas. Bruschi suggested to turn to zinc instead of sheet metal stamping: this choice allowed to improve strength and toughness, it also gave the possibility to have innovative and stunning finishing. The result was 25% cost saving.



Zinc die casting allows to reduce the number of components for subassembly, less parts to control and saving in terms of assembly process: this means less mechanical issues and economical saving in terms of mechanical processing.  

In Bruschi we are also able to assembly directly in our plants, reducing costs and minimizing risks.

Hereunder some case histories clarifying how Bruschi has saved in terms of assembly for its clients:


CTS decided to cut costs by minimizing the number of components for its products and asked Bruschi a solution to reduce costs.

Bruschi suggested a co-design activity in order to develop a special component which could replace three different parts. Bruschi used zinc instead of stainless steel to develop this special component, saving on assembly and cutting costs in terms of processing. The result was 40% cost saving.


Whirlpool needed a solution to reduce cost of assembly and asked to Bruschi for a solution. Bruschi developed an automatic machine directly in plant to speed up the process in order to reduce cost and timing. The result was 8% cost saving.



Bruschi provides tools able to simulate the entire production life cycle with the aim to choose the best possible way to meet the customer's goals. Thanks to our over 70 years in industry of zinc die casting we are able to draw, correct and develop molds for every zinc die cast part.

Our technology and out simulation tools as MAGMASOFT ® helps us to anticipate issue and minimize risks, by finding the most suitable solution in each project.

It is important to use also the rapid prototyping to create a better product and a more efficient one.

Hereunder some case histories explaining how Bruschi has saved using simulation for its clients:


KitchenAid decided to develop a new coffee machine characterized by stunning shapes and innovative finishing. KitchenAid asked to Bruschi a solution to reach its goal. Bruschi simulated with MAGMASOFT® the whole cover to ensure to KitchenAid a great result. The result was 20% cost saving.


Loewe needed a solution to cut cost of components of its TV. Bruschi focused its attention over heatsink by using techniques of rapid prototyping. Bruschi prepared two different prototypes of the same product, one in aluminum and the other in zinc. Testing the difference firstly in simulation and then in thermal chambers in order to compare the heat dissipation difference. The result was 16% cost saving.


Artemide wanted to enhance the purity design, use of finishes and lightweight structures that could give substance to the idea of the designer and challenged Bruschi for ideas. Bruschi carried out a deep process simulation for Artemide to ensure the realization of customer's need. The result was 8% cost saving.

Our technical staff is available to support your designers' inventiveness and to develop innovative and creative solutions together, in case you need any further information, please get in touch.

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