The Challenge

A manufacturer approached Midwest Precision Molding after experiencing ongoing quality problems with a critical molded component supplied by another vendor. The primary issue was excessive flash along the flanges of the bobbin, resulting in inconsistent part quality, increased inspection time, and production disruptions.

Despite multiple attempts by the previous supplier to correct the problem, the flash persisted, creating frustration for both production and quality teams.

The customer needed a dependable supplier capable of consistently producing parts that met specifications without the recurring defects.

Our Solution

Midwest Precision Molding evaluated the customer’s existing part requirements and implemented a manufacturing process focused on precision, consistency, and process control.

Our team optimized mold setup, validated processing parameters, and established strict quality inspection procedures to ensure every part met the customer’s dimensional and cosmetic requirements.

Automation was also incorporated into the process using a reel-to-reel vertical Sodick injection molding machine. This automated approach improved part handling and process repeatability, helping reduce variation and further improve overall part quality.
By emphasizing stable processing and continuous quality monitoring, we eliminated the flash issues that had impacted the customer’s previous supplier.

The Results

Since Midwest Precision Molding assumed production of the component:

• Flash has been eliminated from production parts
• The customer has reported zero recurring quality issues
• Production interruptions related to the component have been eliminated
• Inspection and rework requirements have been significantly reduced
• The customer now has confidence in a reliable, repeatable manufacturing process

Why It Matters

Quality issues such as flash can seem minor, but they often lead to assembly problems, increased labor costs, customer complaints, and unnecessary downtime. Consistent process control and attention to detail make the difference between simply molding parts and delivering dependable manufacturing solutions.

At Midwest Precision Molding, we don’t just produce plastic components, we solve manufacturing challenges. Our commitment to precision, quality, and continuous improvement helps customers reduce risk, improve efficiency, and keep production running smoothly.
Need a Better Injection Molding Partner?

If you’re experiencing quality issues with your current supplier—or simply looking for a more dependable manufacturing partner—Midwest Precision Molding is ready to help.

Contact us today to discuss your project and discover how precision molding can improve your production.