18 Million Brass Lighting Contacts a Year, Weekly JIT to Mexico Plants

A lighting group building fluorescent and LED lamp-holder assemblies needed a thin brass contact stamped and shipped in enormous weekly pull volumes. The part itself is simple; the hard part is holding one print across 350,000 pieces a week for years, from bare #260 brass 0.38 mm thick that marks easily.

We designed the die around the customer drawing and ran the contact on high-speed progressive presses, bare finish, no plating step. Kanban-style weekly releases keep the customer's inventory flat while our coil changes run between press shifts.

Outcome

• 18,200,000 contacts per year, 350,000 weekly
• ±0.005 mm held on the 44.5 mm × 6.0 mm form across long runs
• Bare-finish brass: one less chemical step, lower cost per piece
• Weekly delivery rhythm with engineering response on drawing changes

Specifications

#260 brass (C2600) · 0.38 mm · progressive die, 100% in-house · reel or bulk pack · MOQ 10,000