Total Quality Management
Total quality management applies to everything we do at Ferriot. The end goal is production readiness — parts optimized for functionality, consistency and ease of manufacturing.
Ferriot’s total quality-management process can take a product from concept to final assembly. We can step in at any stage, including in emergency transfers for any of our services, be it molding, painting and contract manufacturing.
The key steps in the quality management process for a molded part include
- Mold qualification
- Part qualification
- Process qualification
- Production quality
Call us or read on to learn more.
Part Development Process
Injection Mold Design
The first question, of course, is whether the mold already exist. If not, we work hand in hand with customers in mold design. Whether we’re developing simple or complex molds, the priorities are:
- Ideal functionality of finished components and products
- Ease and efficiency in manufacturing
- Innovation in the application of engineered polymers to meet any need
Call us to learn about the range of our design capacity — from the engineering of America’s leading shake shingles that can withstand 200-miles-per-hour winds, to plastic components tough enough to replace metal on the boots of gasoline-pump nozzles.
Injection Mold Building
We offer maximum flexibility via our global network of mold makers. With a wide range of capabilities within our talent pool, we match each job to the right skill set for each mold design.
Qualifying the Mold
Regardless of where a mold is produced, its final qualification will be performed at Ferriot. Process engineers will establish the process window and test those boundaries. With a list of variables that affect each different part, they will identify the defining process parameters and zero in on where the part runs the best. Once the process is locked down, capability parts are run for qualification studies. Inspections include
- Dimensional checks
- Tolerance checks, including capability studies
- Gauge repeatability and reproducibility (R&R) studies
Failure Mode and Effect Analysis (FMEA)
This analysis is our first step in measuring the reliability of parts. In addition to following standard methodologies, our trained engineers and technicians add experience and instincts to the analysis of anticipating what can go wrong — and how to correct it before it does go wrong.
At this stage of analysis, the Ferriot team works closely with our original equipment manufacturers’ (OEMs’) counterparts. Ferriot assigns a lead tooling engineer to oversee each project from design to production readiness.
Ferriot qualifies parts with the following equipment
- Large coordinate measuring machine (CMM), running the latest version of PCDMIS
- Optical comparator
- Variety of dimensional gauges, including Trimos height gauges
- Electronic scales
When necessary, Ferriot can make custom tools for quality inspections.
Ferriot documents each step in the qualification process, by using in-house forms or forms supplied by OEMs. Whatever the approval process, we will work with you.
Regularly Scheduled Quality-Control Audits
Ferriot follows critical-to-quality characteristics to ensure compliance to specifications and quality production. For each part, Ferriot conducts audits to ensure adherence to operator instructions and quality-control plans. Design standards are verified with drop tests, ductility tests, dimensional checks and other forms of analysis, depending on the part and its function. Ferriot is proud to be a certified ISO 9001: 2008 quality management system standards compliant.
In addition to design and engineering services, Ferriot identifies and qualifies suppliers for each component required in your assemblies.
The process includes risk management, so that if we’re sourcing particular components for a finished assembly, we start by verifying the capacity and fiscal soundness of several potential suppliers. This can include on-site audits.
In making final selections, we seek bids from qualified vendors.
Ferriot at a glance:Ferriot, Inc. is a full‐service contract manufacturer and molder of engineered resins. Our production capacity, engineering support, and production capabilities include:
- 88‐year history of quality and commitment
- 200,000 square‐foot facility
- round-the-clock operations
- dedicated engineering team
- more than 150 varieties of resins in stock
- global network of suppliers
- auditors to validate quality in real‐time production
- product identification numbers traceable by lot
- injection molding machines from 40 to 2,200 tons
- reconfigurable work cells for final assembly
- paint booths
- ultrasonic welding equipment
- automatic and manual heat stakers
- hot stamping equipment
- 2‐ and 4-color pad printers
- EMI/RFI shielding
- rapid prototyping
- design for manufacturabilty
- advanced applications (e.g., mold flow and warp analysis)
- engineered polymers
- straight injection molding
- structural‐foam molding
- gas‐assist molding
- custom mold design and production of molds up to 58‐1/2” by 78”
- finish painting of parts up to nine feet in length
- EMI/RFI shielding applications
- cosmetic coatings
- ultrasonic welding
- hot stamping
- fixturing and heat staking
- pad printing
- supply‐line development and management
- process qualification
- product testing
- final assembly
- drop shipping
- short runs
- mold qualification
- part qualification
- process qualification
- production quality