AIM Processing Small Plastic Parts Blog

As a manufacturing manager, you know the frustration: Parts arriving with inconsistent quality. Missed delivery deadlines. Phone calls and emails going unanswered. Yet despite these issues, many managers feel trapped with their current injection molding partner because they possess the tooling needed to produce critical parts.

What many don't realize is that the injection molding tool—a significant fixed asset that you purchased—can be transferred to a new vendor. The perceived complexity of this process often deters manufacturing professionals from making a change, even when their current supplier consistently underperforms.

The Hidden Costs of Staying Put

When your injection molding manufacturer isn't delivering as promised, the impacts cascade throughout your operation:

• Quality issues disrupt production lines and damage your reputation with customers
• Chronic delivery delays force you to push back your own shipping dates
• Poor communication leaves you constantly wondering about order status
• Production inefficiencies drive up costs and waste valuable time

Yet the "golden handcuffs" of an established relationship and the perceived difficulty of transferring your tooling keep many manufacturing managers from exploring better options. The sunk cost fallacy—believing that past investments justify continued loyalty despite poor performance—only deepens this reluctance.

When Is It Time to Consider Tool Transfer?

Three key scenarios typically prompt manufacturers to consider transferring their injection molding tooling:

1. Persistent Quality Problems: When parts consistently fail to meet specifications, tolerances or certifications, the downstream effects can be devastating. One electronic device manufacturer experienced this firsthand with components that varied in size across production runs. After transferring their tooling to a new provider with engineering expertise, they discovered the tooling itself had been built with incorrect dimensions. With the right partner, they fixed the issue for less than $1,000.
2. Chronic Delivery Delays: When your molder repeatedly misses delivery dates, your entire supply chain suffers. A security device company endured this challenge with over thirty molds at an underperforming mold manufacturer. After reaching their breaking point, they transferred their tooling to a new partner who requalified all thirty molds in just two weeks.
3. Communication Breakdowns: When combined with quality or delivery issues, poor communication creates an untenable situation. Without timely updates and responsive service, manufacturing managers find themselves unable to plan effectively or provide accurate information to their own customers.

Overcoming Tooling Transfer Obstacles

The prospect of transferring your mold often raises legitimate concerns about outstanding invoices, material costs, process timelines, production interruptions and whether the new vendor can actually produce better results. While valid, these concerns must be weighed against the cost of continuing with an underperforming supplier.

The right injection molding partner will help navigate these challenges throughout the transition. They'll facilitate negotiations for tool release, similar to settling a mechanic's lien, and provide transparent timelines for both transfer and production resumption. Experienced partners also assist with inventory management strategies to minimize disruptions and often purchase existing raw materials to streamline the transition.

Five Critical Steps for Successful Tooling Transfer

A structured approach is essential for minimizing risk during tool transfer:

1. Comprehensive Tooling Assessment: Upon receiving a transferred mold, the new injection molding manufacturer should conduct a thorough inspection to assess its condition. This inspection ensures the tool is operable and compatible with the new supplier's equipment. In some cases, adjustments to either the tool or the injection molding machinery may be necessary.
2. Material Verification and Procurement: Ensure your new molder has the correct resins available or on order before the tool arrives. An experienced molder with an extensive material inventory can significantly reduce delays during transition.
3. Initial Test Runs and Quality Verification: After setup, the new supplier should perform test runs to assess tool performance and identify any issues. A detailed inspection of these initial parts is crucial to verify quality and ensure compliance with your specifications.
4. Clear Documentation and Communication: Detailed records ensure transparency throughout the process. Your new partner should document the tool's condition upon arrival, after any adjustments and during test runs. Regular updates keep all stakeholders informed and allow quick resolution of any issues.
5. Production Integration and Ongoing Optimization: Once the tooling is operational, the new molder should integrate it into their production systems. They should also develop strategies for ongoing optimization, ensuring consistent quality and efficiency. This ensures consistent quality and efficiency over the long term.

The Engineering Expertise Advantage

A successful tooling transfer requires more than just moving equipment from one facility to another—it demands specialized engineering knowledge and experience. Look for a partner with:

• Concierge Engineers: Degreed mechanical engineers who oversee the entire transfer process, from initial assessment to production integration
• Program Engineers and Technicians: Specialists who handle technical aspects including tool maintenance and process setup
• Customer Service and Technical Support: Dedicated teams ensuring clear communication throughout the process

With the right team in place, tool transfer can be surprisingly smooth. One manufacturer thought they would need to increase inventory to cover the transition period, but because their new partner was able to quickly diagnose tool issues and implement process improvements, they experienced minimal disruption.

Taking the Next Step

If you're experiencing quality issues, delivery delays or communication problems with your current injection mold manufacturer, remember that you have options. Tooling transfer is a viable solution that can significantly improve your manufacturing outcomes and supply chain reliability.

The process requires careful planning and the right partner, but the benefits—consistent quality, reliable delivery and responsive service—far outweigh the adjustments that come with transition.

Don't let the perceived complexity of tooling transfer keep you locked in an underperforming relationship. Your manufacturing success depends on having the right partners, and your injection molding supplier is no exception.

Want to learn more about how you can successfully transfer your tool? Check out our latest white paper: Switch Smarter: Successful Tool Transfer for Injection Molding.

AIM Processing specializes in small, complex plastic parts and has successfully transferred hundreds of tools for manufacturers in medical, electrical, automotive and industrial sectors. With expert engineers, extensive automation and a focus on customer service, we deliver big on small parts. Contact our team at 303-684-0931 or visit aimprocessing.com to learn more.