How do you manage changes and revisions in injection molding specifications and requirements?

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Injection molding is a versatile and cost-effective process for producing plastic parts, but it also requires careful planning and coordination to avoid delays, errors, and waste. Changes and revisions in injection molding specifications and requirements can happen for various reasons, such as design modifications, customer feedback, quality issues, or material availability. How do you manage these changes and revisions effectively and efficiently? Here are some tips and best practices to follow.

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1 Communicate clearly and promptly

Communication is key to managing changes and revisions in injection molding projects. You need to inform all the relevant stakeholders, such as your design team, your mold maker, your injection molder, and your customer, about any changes and revisions as soon as possible. You also need to document the changes and revisions in detail, using clear and consistent terminology, drawings, and specifications. You should also confirm that everyone has received and understood the changes and revisions, and that they have updated their records and schedules accordingly.

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Allan Rodrigues

∴ MSc. Eng. Mec. | Projeto de Pe?as Plásticas e Moldes de Inje??o
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Em etapas avan?adas do projeto o ideal é que todos os envolvidos no projeto recebam um relatório detalhado de especifica??es de altera??es, citando os motivos para cada uma, se possível com assinatura. Dessa forma pode-se garantir que um especifica??o defasada mascare bons resultados ou defeitos após o try-out.

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2 Assess the impact and feasibility

Changes and revisions in injection molding specifications and requirements can have significant impact on the project scope, cost, quality, and timeline. You need to assess the impact and feasibility of each change and revision, and weigh the benefits and risks. You should consider factors such as the complexity of the change, the stage of the project, the availability of materials and resources, the compatibility of the mold and the machine, the testing and validation requirements, and the customer expectations. You should also consult with your mold maker and your injection molder to get their input and feedback on the technical and practical aspects of the change.

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3 Negotiate and agree on the terms

Changes and revisions in injection molding specifications and requirements can affect the contractual terms and conditions of the project. You need to negotiate and agree on the terms with your customer, your mold maker, and your injection molder, before implementing the changes and revisions. You should discuss and clarify issues such as the scope of work, the delivery schedule, the payment terms, the quality standards, the warranty terms, and the liability clauses. You should also update and sign the contract documents to reflect the changes and revisions, and keep copies for your records.

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Joseph Bouwhuis

Former Senior Engineer - Systems Integration at Ford Motor Company
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In my experience, the concept of Freezing the design” before cutting the mold-tool steel seem obvious- but customers frequently believe that late changes “need to be handled.” Depending on what design variables get redone late; and how late; sometime the tool originally started become a total loss. And a do-over is the only way to deliver parts to the revised design requirements.

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4 Implement and monitor the changes and revisions

Once you have communicated, assessed, and agreed on the changes and revisions in injection molding specifications and requirements, you need to implement and monitor them carefully and systematically. You should follow the established procedures and protocols for making changes and revisions, such as using change orders, revision numbers, version control, and traceability systems. You should also coordinate and supervise the activities of your design team, your mold maker, your injection molder, and your customer, to ensure that the changes and revisions are executed correctly and timely. You should also verify and validate the quality and performance of the modified parts, using appropriate testing and inspection methods.

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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Effective management of injection molding specification changes also requires a robust risk management strategy. Beyond communication and contract negotiation, a proactive approach to identifying potential risks associated with modifications is essential. Implementing a risk assessment framework helps in foreseeing the implications of changes on production quality, safety, and regulatory compliance. Moreover, leveraging advanced digital tools and technologies, such as simulation software, can offer predictive insights into how changes might affect the molding process, allowing for preemptive adjustments.

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Ryan Erickson

"Fixer" and Technical Sales at Polysource
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I find it helpful to attach emails, meeting notes, and other written documentation that shows the conversation of the change happening in the first place on internal revision changes. Change management is always tricky but if you can drag/drop an email it will save you and your future replacement LOTS of time trying to find that pesky email or print update. 30 seconds worth of making notes now is worth at least 15 minutes later once you've forgotten and start calling colleagues to remember!

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5 Learn and improve from the experience

Changes and revisions in injection molding specifications and requirements can be challenging and stressful, but they can also be opportunities for learning and improvement. You should evaluate and review the process and outcome of the changes and revisions, and identify the strengths and weaknesses, the successes and failures, the lessons learned and the best practices. You should also solicit and analyze the feedback and suggestions from your customer, your mold maker, your injection molder, and your design team, to understand their perspectives and expectations. You should then use this information to improve your injection molding project management skills, processes, and systems, and to prevent or minimize future changes and revisions.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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Considering the complexities and potential disruptions that changes and revisions in injection molding specifications can introduce, it's crucial to also focus on innovation and flexibility in your approach. Employing advanced simulation tools for predicting outcomes of changes can significantly reduce risks and unforeseen costs. Additionally, maintaining a proactive inventory management strategy for key components can mitigate delays, ensuring a smoother transition when specifications change. Regularly scheduled reviews of processes and feedback loops with all stakeholders can preemptively identify potential changes, allowing for more strategic planning and execution.

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How do you manage changes and revisions in injection molding specifications and requirements?

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3

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1 Communicate clearly and promptly

2 Assess the impact and feasibility

3 Negotiate and agree on the terms

4 Implement and monitor the changes and revisions

5 Learn and improve from the experience

6 Here’s what else to consider

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