What Separates Top Plastic Injection Molding Companies From the Rest
Evaluating plastic injection molding companies to identify potential red flags is a crucial step in mitigating risk when selecting a new manufacturer. Exercising due diligence upfront reduces the risk of unexpected setbacks downstream, which can drive up your total costs and damage your brand.
What separates top injection molders isn’t being ISO 9001 certified or delivering on time. Those are the minimum requirements for doing business. While it is understood that not all injection molders can meet these basic requirements, others raise the bar even higher, implementing practices and capabilities that safeguard quality, control costs, and keep programs on track when challenges arise.
Quality Beyond ISO 9001
ISO 9001 is a globally recognized standard that sets the framework for a company’s quality management system. You can compare several ISO 9001-certified plastic injection molding companies, and some will consistently deliver high-quality products, and others may fall short. The issue isn’t with ISO 9001; the issue is with implementation. Some companies are looking for a checkmark and haven’t embraced the spirit of the standard. Others go beyond to ensure quality is built into every process.
Here are some things to look for beyond certification:
- Tight Process Control – Look for injection molders with process engineers on staff who manage molding operations using advanced software controls. These systems enable remote monitoring, data tracking, and automated alarms, ensuring that processes remain within specification.
- Full Process Validation – When process validation is performed on every project, variability is eliminated, and you receive consistent, reliable outcomes.
- Advanced Inspection and Metrology – Look for an in-house metrology lab equipped with automated 3D vision systems and smart scopes. These tools enable precise first-article inspections, PPAPs, and production checks. You receive parts that are validated against exacting standards, reducing the risk of failure in the field.
- Data-Backed Claims – Ask about defect or scrap rates, first pass yields, process capability (Cpk), or passed audit scores. These should give you an idea of how the company delivers on quality.
Premier Plastic Injection Molding Companies Have Transparent, Fair Practices
While a plastic injection molding company may offer a low-cost product, be aware of hidden costs that can add up quickly. Top companies are upfront and fair with their practices.
Rarely does a finished product resemble the initial concept that inspired it. Engineering changes are inevitable and can be driven by design validation, performance issues, efforts to reduce costs from the product, or customer-driven specification revisions, among others. Some plastic injection molders take advantage of this and view design or engineering changes as an opportunity to recoup their margins. A top injection molding company will address design risks upfront to reduce the need for engineering changes. If changes are needed, a top company like Metro Plastics will provide quotes for engineering changes at cost.
Top Companies Consider Tooling Maintenance
Another area where costs and delays can creep in is with mold maintenance. Routine preventative maintenance (PM) is necessary to ensure product quality, keep costs in check, protect the tool’s longevity, and prevent timeline delays. Downtime due to unexpected tool repairs can shut down production of your product and incur unforeseen costs.
The top injection molders understand the importance of PM for tooling and will have a PM schedule and an in-house toolroom. If your injection molder doesn’t have an in-house tool room, you are at the mercy of a third party, which could mean unexpected costs and delays. Top molders maintain control with in-house tooling support.
Prioritizing Engineering Expertise Benefits Customers
When injection molders do not provide genuine engineering support, you are left to make critical decisions without expert processing input. Will the undercut create issues? Can your material be easily molded? Are your tolerances realistic for the process? Without engineering support, you may face design issues, subpar part performance, and costly production delays. Leading injection molding companies distinguish themselves by offering access to a highly experienced engineering team that serves as an extension of the customer’s own team.
Product engineers assist with material selection, design for manufacturability (DFM) analyses, and comprehensive mold evaluations at an early stage of the process. Process engineers maintain tight controls on the injection molding process and work proactively to optimize production parameters, troubleshoot issues as they arise, and ensure consistent part quality throughout the manufacturing run.
Rather than reacting to problems after they arise, top molders with engineering teams proactively identify and address potential issues, helping to ensure smoother project outcomes, higher-quality parts, and more efficient runs.
The Best Plastic Injection Molding Companies Evaluate Long-Term Partnership Potential
A strong injection molding partner does more than make parts; They become part of your team. When evaluating potential customers, these companies look beyond immediate production needs and assess how they can support long-term growth. They consider scalability, adaptability, and the ability to evolve in tandem with your product lines and market demands. This forward-thinking approach ensures that as a customer’s business expands, the molding partner can continue to deliver consistent quality, meet increasing volume requirements, and contribute to product innovation.
What sets these companies apart is their commitment to collaboration and problem-solving. They engage in ongoing dialogue with their customers, helping refine designs, reduce costs, and improve functionality based on customer feedback. Full-service capabilities further streamline operations and reduce the need for multiple vendors. By investing in these long-term relationships, injection molders become more than suppliers; they become strategic allies in their customers’ successes.
See this real-world example of how a long-term strategic partnership can drive innovation, scalability, and operational efficiency. Read this case: “Building Growth Through A Strategic Partnership With Spin-clean International”
See Why Customers Trust Metro Plastics
Even though we have more than 50 years of plastic injection molding expertise, we don’t rest on our laurels. We understand the importance of delivering high-quality products consistently and on time to our customers.
Our injection molding ERP connects directly to every machine for real-time tracking. An experienced and dedicated scheduler manages daily production meetings to ensure orders are delivered on time, giving you visibility and reliability. Our in-house tool room allows us to provide PM and emergency repairs quickly, minimizing downtime.
Our engineering team has more than 100 years of combined experience, so whether they are suggesting a suitable resin or ensuring process parameters stay within the operating range, they draw on their expertise to deliver consistent quality and dependable results for every project. Plus, if engineering changes are required, we never upcharge them. We provide them at cost, saving you money.
If you are looking for a long-term injection molding partner committed to your success, choose Metro Plastics. We go beyond simply making parts. We deliver consistent, high-quality results on time, proactively solve challenges, and invest in your growth, making us the strategic ally your business deserves. Contact us to get started.