The following five-step, streamlined process is indicative of the associated tasks involved.
1. Disclosure of existing documentation
Production part print
Gauge/fixture print
BOM and routing sheet
Golden sample
Tool drawings and tool maintenance record
Molding and change-over instructions
NCMR history
Last 12 months process capability (control dimensions only)
Last GR&R for any inspection gauges or fixtures
Control plan
2. Documentation conversion at new molder
Create BOM in appropriate MRP system
Measure golden samples
Create metrology instructions
Create inspection report
Create visual inspection report
Create work instructions
Set-up tool identification package
Set-up gauge identification and calibration schedule
3. Tool evaluation
Document tool features
Document tool wear
Measure gate sizes
Establish a preliminary preventative maintenance schedule
4. Validation sample
Create visual set-up instructions
Create process window sheet
Document process related issues
Document tooling related issues
Measure samples (one part/cavity)
Run a short Production Part Approval Process (PPAP) run to confirm capability
5. Qualification process
Qualification documentation record sheet
Process Failure Effect Mode Analysis (PFEMA)—by group
Control plan—by group
Process flow—by group
Part print
Insert print (if applicable)
Print acceptance form (PAF)
First article inspection (FAI)
Capability index (control dimensions only)
Gauge Repeatability and Reproducibility (GR&R; automotive only)
Tool evaluation
Material certification
Warrant
There are many reasons our clients choose to move their mould tools to us from the far east, but resolving their problems with quality, delivery & communication tends to be top of the list. When you’re looking around for a new moulder for your existing tools, it pays to do your homework first.
With the transfer of plastic injection molds, manufacturers can embrace the opportunity to improve the quality, pricing, service and lead time that a plastic injection molder may provide. However, it is important for a manufacturer to be aware of the possible technical issues and challenges that can emerge during the process.
While unforeseen circumstances can occur, discoveries made in the transfer process will aid in achieving a high degree of project success.
Diligence in the evaluation phase will ensure a positive outcome with proper planning, communication and investment to achieve the ultimate goal of the project.
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