Seamless Tool Transfers: How Ferriot Helped Ensure Uninterrupted Production for SRG Global Inc.

SRG Global Inc. stands tall as one of the premier manufacturers of plastic parts with high-value coatings, catering to the automotive and commercial truck industries globally. Its commitment to excellence, scientific culture and top-tier standards have earned the company a distinguished position among the leading automotive injection molders. Serving renowned brands like Chrysler, Chevy, BMW, Ford and Nissan, SRG Global doesn’t confine itself to one approach but embraces solving a wide range of engineering challenges in the industry.

The Challenge:

When SRG Global Inc. decided to close its Missouri plant, company leaders realized they needed to relocate that plant’s injection molding operations. They decided to outsource the process rather than move it to another SRG facility and launched a search for a reliable partner. SRG team members were not only seeking a reliable injection molder, but one that could manage the intricacies of the mold transfer portion of the program with minimal disruption. With multiple, intricate tools and parts in the mix, ensuring a smooth transition to a new partner without disrupting its supply chain posed a significant challenge.

Ferriot’s reputation preceded itself. Known for its commitment to excellence, Ferriot’s rigorous approach to injection molding resonated with SRG Global’s ethos.

The Transfer Process:

With nine tools and seventeen parts slated for transfer, Ferriot took point on the project and began to meticulously plan the operation, with a detailed tool transfer schedule created for each of the nine tools. Understanding the importance of uninterrupted production, Ferriot production teams worked with SRG Global’s teams to create a 10-week bank of parts to ensure a steady, uninterrupted supply of parts during the transition. Only once this bank was in place did the final steps of the transfer take place.

While managing the project, Ferriot encountered challenges typical of such complex transfers. SRG provided end-of-arm tooling (EOAT) that Ferriot needed to modify in order to work with their robots and presses. The EOAT’s needed to pull the parts from the mold, deliver to equipment for automatic de-gating, dispose of the runner and set the parts on the conveyor. With the number of parts, this required their automation team to deliver results in a short period of time. This degree of automation provides cost savings on labor. However, SRG Global’s collaborative approach helped overcome these obstacles. Clear communication, transparency and adaptability ensured that the project never veered close to the automotive industry’s dreaded phrase, “line down.”

After the seamless tool transfer was completed in late 2023, Ferriot began shipping to SRG Global Inc. weekly. A well-oiled logistics setup ensures timely deliveries, with volumes soaring high. From 85,000 parts annually on the highest-volume tool to quoting new finishing projects, Ferriot Inc. has proven to be the trusted partner SRG Global was seeking.

Steven Ploucha, director of program management for SRG, knew from his initial observations that Ferriot’s culture and skill set would fit with his company’s. “When I first set foot in their facility and saw the attentiveness of their team and the cleanliness of the plant, you definitely knew that they take pride in what they do,” said Ploucha. “We felt from the outset Ferriot’s commitment to collaboration in order develop a strategic plan and quickly resolve any issues we’d encounter together.”

About Mold Transfer at Ferriot:

Ferriot’s mold transfer process is a hallmark of careful planning and attention to detail. Its comprehensive approach is focused on ensuring mold transfers are completed without disrupting the supply chain or compromising quality.

Prior to initiating any transfer process, Ferriot ensures that it addresses several points:

• Mold compatibility: Ferriot’s experienced team assesses the compatibility of existing molds with its equipment and processes. Mold compatibility helps maintain production quality and efficiency.
• Mold maintenance and wear evaluation: its staff will thoroughly evaluate the current condition of transferred molds, identifying wear and determining the level of preventive maintenance required. Ferriot expertise in mold inspection and maintenance practices help promote optimal performance.
• Process qualification: Ferriot handles all process validation activities, including Design of Experiments (DOE), control plans, process Failure Mode and Effects Analysis (FMEA) and capability studies. Its team also resolves any technical challenges that arise during the mold transfer process. This can include identifying and solving issues related to mold compatibility, part quality, process optimization and any necessary tool adjustments.

Learn more about transferring molds on the Ferriot blog:

• ShopTALK: Mold Transfer Considerations Everyone Should Know – Part 1
• ShopTALK: Mold Transfer Considerations Everyone Should Know – Part 2
• Headaches To Avoid When Transferring A Mold To A New Injection Molder
• Are you ready for your mold transfer? Tool Transfer Success Checklist