From time to time, you are forced to choose alternative sourcing options for projects. Industrial Molding Corporation has successfully converted over 500 transfer tooling projects since 2001. We utilize our fifty years of experience in mold design and plastic processing to evaluate the project, diagnose problems that affect performance of the project, recommend alternatives to improve underperforming programs, or suggest options to speed the transition when critical supply channels must be maintained. 

This is our checklist that we have developed over many years to guides this process.   

Prior to Business Award

• Gain as much information as possible about the project. If it is a problem job, an investigation must be started that yields an accurate root cause in order to correct the problem.   
• Collect all specifications and contract terms applicable to the project.  
• Determine the type of tooling and whether IMC can operate the tool. Is the tooling “stand alone” or part of a proprietary tooling system, which will require the construction of a “base mold” system prior to the transfer. Include in the original quote the costs to modify tooling to operate in IMC equipment.  If tooling is not “stand alone”, capture the cost of “base mold” system and report this to the customer.

Collect the following information from the current supplier in order to prepare the initial quotation:

1. Current cycle time. If the existing cycle information is not available, estimate this by using the wall section of part and accepted freeze times for the specified resin. Make certain the quotation highlights the uncertainty of the estimated cycle time and that later, depending on the tool construction and the process settings required for dimensional shifting, the cycle time may become extended thus yielding a change in the estimated selling price.
2. Any quality rejections or dimensional performance reports. 
3. Cavitation. Confirm sufficient cavitation exists to meet estimated production requirements. 
4. Are molded inserts or secondary assembly operations required. 
5. Allowable regrind percentage, part weight, runner weight, shot weight. 
6. Mold dimensions (Width, Height, and Stack Height)
7. Press tonnage
8. Confirm the status and condition of any secondary operations equipment, gaging and fixtures, hand tools, or assembly aids and equipment. Make certain that it is part of the tool transfer or quote the development of new equipment if required.

• Create the official Quotation and forward to the customer.

Once Awarded

• Create a “Transfer Team” consisting of the customer, and members of IMC quality, manufacturing, and engineering groups.
• The transfer project follows all normal product development procedures and requirements. The tool design and tool review process occurs on the existing tool. Design problems that prevent the project from being successful, along with options to remedy the problems are reported to the customer. 
• Assess the risk to the customer from the current molder.  Assist the customer where possible to guard against “hostage” situations.
• If possible, visit the current molder to evaluate the condition of the tool prior to shipping to IMC.  Note any information concerning the processing conditions, operation of secondary equipment, and use of gages. 
• Collect any information available from the previous supplier concerning preventative maintenance and tool construction.
• Determine what exactly will be included with the transfer.  Pay particular attention to all gauging and assembly equipment.  Often this is not part of the tooling package and will need to be addressed with the customer.  Also confirm the existence of tool drawings and that they will be part of the transfer package.
• Identify any spare parts, components, and excess resin that the customer would like to move to IMC. Under normal circumstances, IMC should only receive resin in un-opened containers. If items are consigned, the IMC quote will need to be adjusted until the consigned materials are consumed. 
• Confirm the method of transport and packaging.  Evaluate the potential for tool damage during shipment, and advise the customer if we recommend that IMC should have oversight of packaging and/or shipment of the tools and equipment. 
• Develop a plan for the shipment of tools, supporting equipment, and resin.
• Verify that all intended items are shipped and identify the expected arrival date of the shipment at IMC. Communicate this date to the Customer.
• If timing for the first production run is critical, discuss all options for “streamlining” the PPAP process with the customer.  This could include on site PPAP approval or an open deviation for the first run.  
• If secondary operations equipment are included in the program, assess the condition of the equipment and determine if outside services are needed for repairs, spare parts, or internal training for the operation of the equipment.
• Perform a complete dimensional layout on the last sample from the previous molder. If the last sample is not available from the previous supplier, attempt to reproduce the process from the previous supplier. This provides a baseline for the product dimensionally, and is used to resolve dimensional issues. 
• Select benchmark dimensions to use for the initial dimensional inspection results on the first IMC samples. Compare these results to the results from parts produced by the previous supplier, then share these dimensional results with the customer noting differences and potential opportunities
• Explain the dimensional results clearly to the customer and establish a plan with them to resolve any out of tolerance conditions. Make certain the customer understands the reasons why IMC’s first sample may not match information from the previous molder.
• Identify tool changes that are needed to correct dimensional issues so as to achieve full PPAP approval.  
• If tool changes are required, confirm that the costs to change the tool have been agreed to by the customer.  Once approval to change the tool has been accepted, coordinate the timing of the tooling corrections with the customer, and make plans for a buffer inventory if needed to support the customer in the interim.
• Review any previous SPC data, control plans, annual revalidation reports and corrective actions to modify risk priority values on IMC’s FMEA as required.
• Once sampled, compare actual processing information to the estimates used to develop the initial quotation. Advise the customer where unexpected variances in the manufacturing methods could/should lead to adjustments in the pricing estimates.  
• Seek full approval of the PPAP from the customer in order to initiate volume production shipments.

Congratulate the team and begin servicing production order releases.