Vention assembled a dedicated, cross-functional team that held weekly meetings to update the customer on the project and to provide Design for Manufacturing support. Project management skills were critical.
Tools that were previously 1- or 2-cavity tools were redesigned as more efficient 4- and 8-cavity tools. The tools were also redesigned from cold-runner tools to hot-runner tools, which require less material and reduce waste. Vention was able to design inserts so that one tool could be used to make multiple molded components, saving additional costs.
The Vention Team used Value Engineering and our Single Source Tooling Program to achieve optimal balance of performance, quality, delivery, and cost to quickly fabricate complex, high quality, multicavity hot runner production tools that met the requirements of a rigorous validation. Vention’s logistics management allowed for fast turn-around, which enabled the team to provide the customer with functional test samples of the molded components and to begin executing validations within days after the molds arrived.
Vention leveraged its Tooling Center of Excellence and team members’ technical expertise in tool fabrication and injection molding to overcome challenges that arose during the validation phase. For example, one molded component was prototyped, but not fully designed, when a 4-cavity tool was launched. Working with both its tool supplier and the customer, the Vention team implemented several significant design changes and quickly provided molded component samples for customer testing.
Over the course of the project, the customer made some design changes that added pressure to the timeline. Several other molded components also had final details developed after tools were made or after the first samples were tested. Despite these challenges, the team was able to submit complex Product Quality/Product Part Approval Process (PQ/PPAP) reports on time. Vention also completed secondary operations such as pad printing and ultrasonic welding.
The Vention team’s ability to remain flexible, to work together, and to quickly execute design changes were key to success in meeting the timelines.