Authored By: SDI Plastics

The automotive industry relies heavily on Plastic injection moulding to produce the countless plastic components found in modern vehicles. From interior trim pieces and lighting components to under-the-hood applications, injection moulded plastics play a pivotal role in automotive manufacturing.

With the right automotive injection moulding partner, manufacturers can achieve high quality, precision components with minimal defects and scrap rates. Choosing an injection moulding company with proven expertise in automotive projects is crucial.

This guide will explore key factors to consider when selecting an automotive injection moulding supplier and provide actionable tips to help find the right partner.

Assess technical capabilities and experience

When evaluating potential automotive injection moulding companies, their technical capabilities and experience should be your first consideration. Specifically, look for the following credentials:

• Specialisation in automotive moulding – Seek companies whose primary focus is on automotive components and systems. They will have the right equipment, expertise, and quality control measures tailored to the automotive industry.
• Engineering design capabilities – Mould design and component engineering expertise in-house allows for greater collaboration and accelerated project timelines. Opt for a company that provides complete design-to-manufacturing capabilities.
• Material knowledge – Look for extensive experience moulding the unique plastics used in automotive, such as PP, ABS, TPO, TPU, PC/ABS. The right material choice is critical.
• Project management skills – Managing automotive moulding projects requires meticulous attention to detail. Ensure the company has qualified program/project managers to oversee your programs.
• Quality certifications – IATF 16949 is the key automotive quality standard. ISO certifications also validate dedication to quality. Make sure the company holds the right certificates.

When evaluating experience, look for demonstrated success moulding components similar to yours in complexity and production volumes. The more relevant experience they have, the lower your program risks will be.

Confirm their manufacturing capabilities

The manufacturing capabilities of the injection moulding company must align with the production needs of your automotive components. Carefully examine their capabilities in these key areas:

• Facility size – Larger program volumes require a facility of adequate size to accommodate production demand. Ensure the company has enough physical capacity and press tonnage for your volumes.
• Equipment technology – Look for all-electric, high-precision injection moulding machines and sophisticated process monitoring and control systems. This provides optimal precision and repeatability.
• Tooling expertise – The company should have extensive tooling engineering experience and be able to manage, maintain, and refurbish moulds with minimal downtime.
• Secondary processes – Many automotive components require additional processes like paint finishing, metallization, bonding/fastening, or other assembly steps. Verify these capabilities are available in-house.
• Quality assurance – Automotive OEMs demand uncompromising quality levels. Make sure robust quality processes are in place, like detailed control plans, GD&T inspections, functional testing, etc.
• Continuous improvement – Leading companies are constantly refining their processes and capabilities. Seek out partners with a culture of continuous improvement to drive ongoing gains.

Evaluate their program management approach

Launching a new automotive moulding program requires rigorous program management from start-up through production. When evaluating suppliers, consider their project management methodology:

• Program leadership – A dedicated program manager should oversee all aspects of your program, from design to delivery. Seek out responsive, collaborative leaders.
• Engineering support – Upfront engineering collaboration is invaluable. Confirm their engineers will actively partner in product design reviews, mould flow analysis and DFMA guidance.
• Prototyping capabilities – The ability to produce both rapid prototypes for design verification as well as high-precision pre-production samples is critical to program success.
• Launch support – The ramp-up to production can make or break program quality and timeline goals. Look for start-up expertise like process capability studies, control plan development, and production trial runs.
• Ongoing communication – Regular project updates and open lines of communication are a must. Verify they provide complete transparency into program status and issues.
• Continuous improvement – Your automotive moulding partner should proactively drive manufacturing and quality improvements over the program life, delivering year-over-year gains.

Prioritise cultural fit and collaboration

While technical capabilities are imperative, cultural alignment and collaboration should also factor into your decision-making. Be sure to assess:

• Partnership mentality – You want a company that acts as an extension of your team with shared goals, not just a vendor. Gauge their commitment to a true partnership.
• Customer focus – Look for a relentless focus on the customer experience and delivering program success through collaboration and responsiveness.
• Problem-solving attitude – Unforeseen issues will arise, and speedy resolution will be critical. Evaluate their dedication to rapid problem-solving.
• Communication style – Frequent, open, and transparent communication should be standard practice. Confirm they provide the level of communication you expect.
• Continuous improvement mindset – Moulding is a continuously improving process. Ensure the cultural emphasis is on driving ongoing quality and cost improvements.
• Flexibility and responsiveness – In injection moulding, time is money. Seek out partners praised for their agility and rapid response to customer needs big or small.

Taking the time to properly evaluate both the technical and cultural fit will help ensure that an injection moulding partner will align with your program goals and expectations.

Audit their quality control and assurance processes

For automotive moulding programs, quality is non-negotiable. Be diligent in your audit of their quality systems:

• Incoming materials – Raw resin and other incoming materials must be thoroughly inspected and tested per your specifications before processing. Verify these procedures are comprehensive.
• In-process quality checks – Your components should be monitored throughout production for any process deviations that could affect quality. Confirm rigorous checks are in place at each stage.
• Automated process monitoring – Advanced technology like cavity pressure sensors, thermocouple, and vision inspection systems help maximise process control. Seek out these automation enablers.
• Tooling management – Tool maintenance procedures should be robust to avoid quality issues as moulds age. Confirm that programmed tool maintenance schedules are followed.
• Dimensional inspections – All critical part dimensions and tolerances should be thoroughly validated using GD&T practices and automated systems like CMMs and optical comparators.
• Functional performance testing – Depending on your product, testing for fit, form, function, and other metrics validates real-world quality. Verify these functional checks are completed.
• Traceability – Raw materials and finished components should have robust traceability in case any quality issues arise that require root cause analysis. Confirm tracking systems are in place.
• Documentation – Detailed control plans, process instructions, inspection reports, and other documentation should be maintained. Audit documentation for completeness.

By thoroughly vetting their quality procedures against the program requirements, you gain assurance in your production quality.

Research their financial health and business stability

While rarely top of mind, the financial health and business stability of your injection moulding partner is certainly worth considering to mitigate program risk:

• Company history – Longstanding players with decades in business suggest financial and operational stability. Newer companies can be riskier. Favour companies with depth of experience.
• Ownership structure – Family-owned and managed organisations often foster a culture of quality and longevity. Note if this gives the company focus beyond short-term gains.
• Financial strength – Request financial statements to assess profitability, growth, credit, and other key indicators of financial fitness. Favour positive momentum.
• Facility investments – Modern equipment, expanded capacity, and facility upgrades all signify a company investing in its future and customers. Look for these growth signals.
• Business diversification – Serving multiple industries can smooth out business cycles. Diversified companies may offer greater stability versus a niche player.
• Leadership team – An experienced and forward-thinking management team generally indicates a strategically run operation. Gauge their leadership pedigree.

While there are never guarantees, scrutinising their financials and business approach can provide greater confidence in their longevity as your program partner.

Compare pricing models and programs

When comparing automotive injection moulding suppliers, the price will certainly be a factor. But look beyond unit price alone:

• Total program cost – What is the total landed cost, including design, tooling, changeovers, secondary operations, freight, and duty? Gauge total cost impact.
• Transparent pricing – Seek transparent quotes covering every program deliverable – no hidden costs later. Beware extremely lowball bids.
• Price stability – Requests for frequent price increases can disrupt production and strain partnerships. Favor long-term price stability.
• Cost reduction efforts – Your partner should actively pursue cost savings through efforts like DFMA, process optimisation, and supply chain improvements.
• Tolerances and scrap – Overly tight tolerances drive costs up. Ensure tolerances align with function, allowing optimisation. Also scrutinise scrap rates.
• Payment terms – Favourable commercial terms like extended payment periods help cash flow. Seek terms that provide flexibility.
• Resource allocation – Your program should get appropriate resources and priority. Be wary of partners overextended across too many clients and segments.

The right partner provides quality components at a fair, competitive price aligned with program requirements and business terms.

Conduct site visits and assess customer service

Before making a final injection moulding partner selection, it is wise to tour their facility and assess customer service firsthand:

• Facility tour – Walk the floor. Observe general upkeep and housekeeping. Look for optimised material flows and evidentiary pride in their operations.
• Staff engagement – Chat up team members. Gauge experience levels and company morale. A happy, focused team bodes well for your program.
• Witness operations – Observe components being made. Evaluate process capability and adherence to quality procedures.
• Meet leadership – Put faces to names. Develop rapport with key program team members and gauge professionalism.
• Request references – Speaking with current automotive clients offers valuable insight into service levels and partnership experience.
• Review presentations – Supplier presentations allow you to further gauge expertise, professionalism, and responsiveness to your needs and questions.
• Assess correspondence – Even pre-award interactions like quote responses can demonstrate responsiveness, clarity of communication, and attention to detail.
  While time-consuming, an on-site assessment and discussions with the team will provide a clearer picture of fit and confidence in the partnership.

Conclusion

Choosing the right automotive injection moulding partner is a complex decision critical to program success. By considering the expertise, capabilities, collaboration, quality, and service factors detailed here, manufacturers can better assess suppliers and mitigate program risks. With rigorous due diligence, you will be primed to select the ideal partner to meet quality, cost, and delivery goals for your automotive programs.

For Companies seeking a trusted, proven injection moulding partner, SDI Plastics offers experience in supporting complex automotive projects. Contact our talented team today to learn more about our capabilities.