In cold forming of involute splines, the manufacturing process parameters are critical in order to achieve high-quality finished products and spline geometry specifications. Cold forming has a key advantage over cutting and shaping based on the re-structuring of the metallurgy when formed by compacting the material’s grain density. This has been shown to increase the strength of the formed part by 25% to 35% when compared to other processes. The microstructure of the metal is altered rapidly to ensure the strongest point within the structure of the spline, which is located at the root where the mating component occurs. This is vital for parts that rotate under high torques, forces and stress loads. A simulation model of the contact between the tool (die) and a gear blank is presented in conjunction with clamping and stress analysis to develop a fundamental theoretical understanding of the phenomena of material flow. Moreover, the failure mode effect analysis was established and combined with the development concepts illustrated from design to the manufacturing stages. Furthermore, this paper provides a background on the cold forming process and reviews the state-of-the-art technology in gear manufacturing. Elements of tool life and methods of optimisation in the mass production of gears are highlighted. The specifications, tolerances and dimensioning are included, demonstrating the phases that led to achieving the final design intent. Finally, analysis at various mass production processes is also undertaken to optimise and maintain the required quality specifications that the industry demands.