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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, India)
  • Supply chain management to ensure continuous and timely delivery to Mexico