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Qmed Staff
May 6, 2014
4 Min Read
.svg?width=850&auto=webp&quality=95&format=jpg&disable=upscale "How Data Can Ensure a Successful Supplier Tooling Transfer")
OK, who's heard of a supplier tooling transfer that's gone off the rails? Pretty much everyone it seems...
Every major tooling transfer presents unique situations and challenges, and when it's not our core business, we tend to focus on what is tangible. We might think to ourselves: "Hey, if we change to that molding supplier over there, we can cut our costs and increase our profit. Let's send an audit team to the new supplier and make sure they can do what they say they can do. Then we can pull the trigger with confidence."
The idea is simple, and the intent is good, however, even with a world-class audit team, some significant data has been overlooked, which is generally the root cause of why things go awry.
Most medical device OEMs own hundreds of off-site mold tools with multiple suppliers, with each supplier filling a critical niche that made them a compelling choice in the first place. These mold tools run constantly, and most often are well serviced. Once they've been operational for upwards of a million cycles, (like a car with 250,000 miles), however, longevity and risk come into the equation. That said, once the business decision has been made to relocate tooling, orchestrating that successful tooling transfer depends on accurate intelligence.
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When it comes to off-site tooling, it pays dividends to know what you have, know where it is, and know what condition it's in. Image from Tooling Transfers. |
So how do you mitigate risk when you want a new supplier to run "used" mold tooling?
You can make the intangible less so by:
Performing a tooling audit at the outgoing supplier, to capture the essential data points relative to hardware (mold tool and press outputs), peripheral equipment, spares, material designations, documentation, performance attributes, and all relative intelligence prior to a vendor to vendor tooling transfer, or immediately before or after an acquisition.
Completing a tooling evaluation to establish "current tool condition," classification, age, number of cycles, and performance concerns that will enable action to address high scrap rates, mechanical breakdowns, and supply chain interruptions. This allows an OEM to preempt issues, understand risk exposure, and plan accordingly. This will often provide the justification to support capital appropriation and return on investment for replacement tooling where risk exists.
Capturing "tribal" knowledge from the outgoing supplier. Mold tool history, process parameters, handling techniques, fixturing, and inspection and packaging techniques typically don't transfer with the tooling.
Fulfilling a comparison analysis between your existing supplier and the new supplier. No doubt you have audited the new supplier, and you have a history with the outgoing supplier, but most often it's the details that get missed that cause costly delays. Examples include capacity constraints, manufacturing end of arm tooling, peripheral equipment, cleanroom procedures, and so on.
Developing a re-qualification plan. It seems simple enough, but more often than not little consideration is given to jigs and fixtures, measuring techniques, and misaligned documentation.
Forecasting and balancing your inventory needs. Poor tool transfer planning often results in production line interruptions and missed order fulfillment.
Assigning an engineer or project manager that can focus single-mindedly on this transfer. Working with an engineer that understands the inherent issues associated with used tooling, and speaks the same proverbial language you do, will always pay dividends. This key individual is the keeper and interpreter of the data.
By capturing the essential up-front intelligence, creating a robust plan, and engaging the right talent, you can alleviate guesswork, cut costs, shorten your lead-time, and mitigate risk.
Refresh your medical device industry knowledge at MD&M East, June 9-12, 2014 in New York City. |
Paul Mulville is the owner of Tooling Transfers, a tooling services company based in Maine, USA. A graduate of Carshalton College, Surrey, UK, his career has encompassed global project management (India and China), tooling manager, tooling engineer, and toolmaker, and he has worked both sides of the fence--for custom and captive molders, and also for giant OEM companies, serving medical device, consumer goods, electronics, and automotive industries.
See Tooling Transfers' Qmed Profile for more information.
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