Auto Plastic Parts Prototype Tooling

Exporting Five Precision Plastic Components to a US-based Tier-1 Supplier’s Plant in Mexico

Client: CONFIDENTIAL
Industry: Automotive
Region: Mexico
Process: Production Tooling, Injection Molding

Requirement

    -Requested to support a short time pull ahead part project off prototype tools to meet production specifications
    -Final production tooling to be sourced by the` customer expected to require up to 6 months overlap for product supply
    -Required effective collaboration with global teams operating in North America, Europe and India
    -High dimensional accuracy required and balancing check needed in impeller

Project Details

Part Details

Part Name: Impeller, Cush Fan Top Housing, Top Housing, Bottom Housing, Top Hat
Application: Mass Production

Manufacturing Details

Processes: Prototype / Production Intent Tooling with customized gating options including a Hot Runner manifold, Injection Moulding, Imbalance Check
Material: 33% Glass Filled Nylon PA66, Polypropylene

Delivery Details

-Tooling developed within 6 weeks and production started within 12 weeks from project kick-off
-4,00,000 units produced across 5 parts using the same tool

Approach

    -DFM and Moldflow analysis for the tooling -Prototype / Production Intent Tooling developed
    -Imported material as specified
    -Managed production planning and scheduling effectively to meet given deadlines
    -Packaging for export
    -Parts shipped directly to the plant in Mexico

Impact

    -Developed tooling within 6 weeks from kick-off
    -Started production within 12 weeks from kick-off after fine tuning components
    -Began as a prototype part requirement and developed to 0.4M parts from the 5 tools
    -Coordinated with global design teams operating in three time zones (Americas, Europe, China)
    -Supply chain management to ensure continuous and timely delivery to Mexico