Learn how GW Plastics helped one customer gain a market advantage through competitive reshoring
From individual components and sub-assembly applications to complete turnkey Contract Manufacturing projects that include product design, mold building, testing, component production, assembly, decorating, packaging, and order fulfillment, GW Plastics is working with the world’s market-leading companies as a natural extension of their own production resources and capabilities.
A current customer and global leader in respiratory care solutions approached us with a request to re-shore an innovative medical device that was originally launched in Asia. Demand for their product was quickly outpacing available capacity, and manufacturing it domestically offered a strategic advantage in the marketplace. How could they manufacture the device in the US and maintain a commercially viable product?
The Challenge
GW Plastics knew that the only way to satisfy project budget and quality requirements was to focus on overall product cost reduction. Working hand-in-hand with the customer program team, GW Plastics examined every aspect of the product design and the production process, preparing a detailed proposal based on Design for Manufacturing (DFM) improvements. No stone was left unturned, and the team suggested changes to component design, materials, tooling design and cavitation, assembly, packaging, and even to the Instructions for Use (IFU’s).
Why GW Plastics?
Few injection molders are capable of meeting the complex project management and manufacturing demands required to succeed with this type of project. Similarly, few contract manufacturers possess the in-house precision tooling capabilities and advanced molding technologies needed to create products with the highest levels of quality and design integrity. In fact, GW Plastics’ unique combination of core capabilities – Product Development, Precision Tooling, Scientific Molding, Contract Manufacturing, and Global Reach – allowed us to leverage a wider variety of techniques and processes to reduce overall product cost and time to market. In this case, multi-shot and multi-material molding allowed us to create a more functional, higher-quality product while avoiding costly assembly steps.
The use of automation to eliminate labor in the injection molding and assembly processes was also a key ingredient in achieving program financial objectives. The (6) precision injection molds – including the two-shot tool mentioned above – were designed and built internally and at approved tooling sources in the US and China. The automated assembly and packaging lines were developed domestically and currently reside in our Tucson, AZ production facility.
Getting It Done.
By cultivating a deep understating of our customers’ business, GW Plastics has refined a repeatable, customer-centric New Product Development (NPD) process for ideation, concept/product development and exceptional program management that is focused solely on getting products to market quickly, efficiently, and at the highest quality possible. Our successful reshoring of this product is attributable to the NPD team including:
Program Manager – Single point of customer contact responsible for coordinating weekly customer and internal team meetings
Tooling Engineer – Assigned to manage the build and validation of the injection molds. This individual works closely with the Program Manager throughout the entire product lifecycle.
Automation Engineer – Assigned to manage the design and build of the assembly and packaging lines
Manufacturing Engineer – Responsible for preparing the production facility and integrating all of the necessary injection molding machines, assembly line, and packaging line
Advanced Quality Engineer – Responsible for developing and ensuring all validation protocols and supporting IQ, OQ, and PQ
Quality Engineer and Quality Manager – Facility-based representatives responsible for developing and implementing all work instructions, purchased item approvals, and validation submissions
Business Development Manager – Responsible for all commercial support
Additional technical support from Engineering Management, our production Plant Manager, the Corporate Director of Quality, and our Purchasing team were integral to our overall success.
We rose to the challenge for one major medical manufacturer. We can do it for you. Find out how GW Plastics has the experience to deliver.
Give us your next challenge. Let’s innovate together.
For more information, contact:
Tim Reis, VP Healthcare Business Development – Tim.Reis@GWPlastics.com
