Tooling Development Process

SSP TOOL DEVELOPMENT PROCESS : Ensuring high quality and user needs

December 16, 2024

Once an order for stamping die or injection mould is fixed, The below is a typical tooling development process. In this way, the information between customers and suppliers can be communicated effectively and efficiently

1. Order Review Meeting.
– The process starts with a meeting between the internal team and the customer.
– The goal is to review the project requirements, including specifications, expectations, and deadlines.
– The team gathers all necessary inputs to ensure alignment with customer needs.

2. DFM (Design for Manufacturing) Report.
– A DFM report is prepared to evaluate the manufacturability of the design.
– It checks for potential issues in production, such as material selection, design complexity, and cost.
– If the report highlights any problems, the design is sent back for revisions.
– If no issues are found, the process moves forward.

3. Customer Approval (After DFM)
– The DFM report is shared with the customer for review and approval.
– The customer provides feedback or confirms readiness to proceed with the next steps.
– If approval is not granted, necessary modifications are made.

4. Project Planning
– A detailed project plan is created, including timelines, resource allocation, and milestones.
– This step ensures the team knows the sequence of tasks and delivery expectations.

5. Structure Drawing/Layout
– A preliminary design layout is created to define the tool’s structure and overall functionality.
– This layout serves as the foundation for the detailed design process.
– If issues are identified, the design is revised until it meets requirements.

6. Internal Design Review
– The internal team reviews the structure drawing or layout.
– This ensures that the design meets engineering standards and is ready for detailed modeling.
– If any problems are found, the design goes back for further revisions.

7. 3D Mould Drawing
– A 3D model of the mould is developed using specialized CAD software.
– This model provides a realistic representation of the tool and is used for visualization and validation.

8. Customer Review (3D Mould)
– The 3D model is sent to the customer for review.
– The customer examines the model to ensure it meets their expectations.
– If changes are needed, the design is updated accordingly.

9. 2D Mould Drawing
– Once the 3D model is approved, detailed 2D drawings are created.
– These drawings include precise measurements, tolerances, and specifications for manufacturing.
– They act as a blueprint for the fabrication process.

10. Tooling Fabrication
– The tool is fabricated based on the approved 2D drawings.
– This involves machining, molding, and other manufacturing processes to create the tool components.

11. Tooling Assembly
– The fabricated parts are assembled to form the complete tool.
– The assembly process ensures all components fit and function together as intended.

12. FOT (First-Off-Tool) Samples
– Test samples are produced using the newly assembled tool.
– These samples are used to evaluate the tool’s performance and output quality.

13. FAI (First Article Inspection) Analysis
– The first-off-tool samples undergo rigorous inspection to verify they meet specifications.
– This includes dimensional checks, functionality tests, and quality assessments.
– If any issues are identified, the tool is sent for improvements.

14. Tooling Improvement
– Necessary adjustments or refinements are made to the tool based on FAI analysis.
– This step ensures the tool consistently produces parts that meet quality standards.

15. Customer Approval (After FAI)

– The final tooling and sample parts are sent to the customer for approval.
– The customer verifies that the tool meets their requirements.
– If any issues remain, they are resolved before final approval.

16. Package and Shipping
– The completed tooling is carefully packaged to prevent damage during transportation.
– It is then shipped to the customer along with any associated documentation.

17. Lesson Learned
– The team conducts a review of the entire project to document lessons learned.
– This step helps identify successes and areas for improvement, ensuring better efficiency in future projects.