T-1:

This is the initial test of a newly built or reworked tool. The purpose is to test the mechanical components of the mold to ensure that it will function properly. The parts run during this test are to be reviewed in the raw state; no de-gating or de-flashing is done. That way, everyone can see exactly what the mold produces. Data is gathered at this time to begin building a process plan for future mold use.

T-2:

After obtaining customer feedback and approval of the T-1 test, the tool undergoes a T-2 test. This is where the molding process is centered and repeatable results are obtained. To obtain process control, PPI uses a combination of melt temperature, shot speed, and mold temperature. PPI’s molding technicians continue to establish the molding process plan. Coordinated with this tooling run is the completion of all fixtures and development of any secondary operation and/or finishing process plans. The molded parts are then inserted, painted, finished and packaged. Parts supplied at a T-2 test are to be reviewed for form, fit, function, and all cosmetic and secondary requirements. All data is recorded for use at the next step.

T-3 – Beta Production Run:

After T-2 approval by the customer, the tool is put back in the molding machine for the final qualification step, the T-3. At this point, the quantity run is normally the first production release of the first production order. The molding process is optimized to produce the best, most consistent results possible. T-3 parts are representative of what the customer can expect in subsequent production runs. A Cp/CpK study of critical dimensions is done at this time and the results are submitted to the customer. Our target is for having Cp/CpK results be 2 and 1.5 respectively, or higher. After customer approval of T-3, the job becomes a production job and the qualification process ends. All data recorded during the T-tests is used to build the final Part Process Plan, which is used in all future productions.

Critical Dimension Inspection:

When required, the inspection of critical dimensions is begun after completion and acceptance of PPI’s Cp/CpK study. This study demonstrates that our molding process is in control and our parts are consistent. The critical dimension inspection of the part is completed on all dimensions mutually agreed by the customer and PPI.

All this attention to the mold and molding process is crucial to the quality of the parts produced. With customer involvement throughout the process, the result is a win-win for everyone, and a high probability of future successful production runs.

Quality Assurance