In recent years, automotive seat components have been manufactured by the fine blanking process, allowing an improvement of dimensional accuracy at sheared surface in series production. However, the rollover has increased and die failures have occurred more frequently when manufacturing gears by fine blanking. Consequently, important goals for manufacturing seat recliner parts with gears have been to decrease the rollover as well as to improve the tool life. In this study, the half blanking and shaving processes were introduced to improve aforementioned problems for the lower tooth, the main component of a seat recliner. For this purpose, the half blanking process was optimized using the finite element (FE) analysis and design of experiment (DOE). The optimized conditions resulting from this study were an offset of 0.2 mm, a clearance of 0.1 mm and a penetration depth of 4.5 mm. Fine blanking experiment conducted under the optimal condition resulted in a rollover depth decrease from 1.9 to 1.3 mm, and no die failure occurrence.