Proper Quality Management Extends Injection Mould Life

In mold manufacturing, tools naturally wear over time, but effective quality management plays a critical role in extending their service life, improving product quality, and controlling costs. Quality assurance in tool production should focus on the following key areas:

1️⃣ Effective Data Management

• Why it matters: Accurate and accessible documentation ensures consistent communication across departments and prevents costly design and production errors.

• What to manage:

• Production data

• Process data

• 2D/3D drawings and models

• Design revisions and maintenance history

• Risk of poor management:

• Data inconsistency and loss

• Disrupted collaboration between teams

• Increased errors in tool design and maintenance

• Recommendation:

• Establish a centralized PC-based document management system

• Maintain a complete and version-controlled drawing library

• Standardize 2D CAD files to avoid mismatches and confusion

2️⃣ Ensure Data Consistency and Integrity

• Use rigorous testing and validation methods to ensure:

• All tool drawings, production documents, and processing parameters are complete, up-to-date, and accurate

• Regular audits and checks should be implemented to align design, process, and production documentation

3️⃣ Timely Cost Tracking and Obsolete Tool Control

• Collect and log the manufacturing cost of every tool throughout its life cycle

• Benefits:

• Identify obsolete or underperforming tools early

• Reduce unnecessary redesign or rework

• Maintain cost visibility for budgeting and decision-making

• Encourage workshops to:

• Use modern and precise technologies for tool design

• Monitor tooling changes and track actual vs. estimated costs

4️⃣ Labor Force Planning and Coordination

• Integrate the planning of:

• Design

• Processing technologies

• Production scheduling

• Labor resources

• When all aspects are well-organized, it enhances:

• Cross-department communication

• On-time project completion

• Tool quality and delivery reliability

5️⃣ Develop a Comprehensive Tool Production Management System

To ensure long-term quality and efficiency, develop an integrated and digitalized tool production system that includes:

The final goal is to achieve a comprehensive delivery tracking system that links design, production, and delivery in real time.

6️⃣ Establish a Failure Mode and Effects Analysis (FMEA) System

• Implement FMEA to proactively analyze and prevent tool failures

• Tools:

• Cross-functional meetings

• Knowledge-sharing bulletins

• Database of past failures and resolutions

• Incentive programs to encourage continuous improvement

• Purpose:

• Avoid recurring mistakes

• Improve problem-solving efficiency

• Reduce tool repair and maintenance downtime

✅ Summary

A strong quality management framework helps to:

• Extend tool life

• Minimize design and production errors

• Control costs

• Improve delivery timelines

• Enhance customer satisfaction