Case Studies
During our many years in the manufacturing sector, we have served all
types of customers, from the major
auto manufacturers to small start-up companies that operate out of a home garage.
Case Study: Tough Problems are Easy; The Impossible Takes a Couple of
Days
BMJ Mold received a call from a tool engineer of one of our customers who
overheard four other engineers talking about a part that was tooled twice
and was still not right. One of the engineers stated that they needed
good parts in two days.
- This tool engineer had worked with BMJ Mold for several years and knew our capabilities. He told the four engineers "I know the right shop to fix this."
- They in turn called our shop manager and told him they needed to see him ASAP
- Our tool engineer rushed to the customer's place of business and arrived within fifteen minutes of their call.
- After he received an explanation of the problem and gathered other necessary information, he returned to his desk at BMJ and immediately
developed a workable solution to the problem
- Within two days, BMJ built a new mold, which enabled the engineers to deliver the correct critical parts on time.
Under normal conditions, it is nearly impossible to build a mold in just two days, but the engineering team's dedication and extra effort overcame the long odds against them.
Case Study: Creative Solutions for Difficult Design Problems
During the process of receiving quotes to build the plastic injection
mold for a new part, an automobile
transmission switch cover, a manufacturer was having a difficult time engineering
the part's design because it contained quite a few undercuts.
- As designed, the part was almost impossible to tool properly
- It would have been cost-prohibitive to build a mold that would work well and last a long time
- Upon receiving the RFQ, our tool engineers compared part design to its desired function.
- We determined the existing design would not produce a decent part at a decent cost
- We offered an alternative solution that included a living
hinge within the mold and laying the part on its side to make it
moldable
As a result of our innovative and cost-effective suggestion, we secured
the the project and built the mold, which is still
running and functioning well today.
Case Study: Cost-Saving Solutions for Complex Part Production
One of our customers came to us with a key fob, a very complex part with
internal and external cams. They were trying to reduce the cost of molding
the parts to win the business.
- We designed and built a stack mold where one side molded the front and the other side molded the back
- The mold was designed so that it could easily be split into two molds if the stack mold presented problems.
However, the mold consistently performed successfully and profitably, which saved
their customer well over $50,000 a year.
Case Study: Solutions to Problems in the Automotive Industry
We received a panicked phone call from an automotive customer one
afternoon. They had a complaint from the OEM about light leaking around a radio trim
plate.
This problem had to be fixed "NOW" as the cars were
about to go into
production.
- They were requesting a mold for a very thin-walled light shield to fill the gap around the inside of the trim plate
- We informed them that we could build the mold, but were not sure they would be able to fill it due to the narrow width
- They decided to go with this option and asked us to build the mold
- Our engineers worked diligently to overcome the design challenges;
had a prototype mold designed and built within one week
The new parts were successfully produced from the final mold and
the
problem was solved!
An automotive customer sent us a mold for a tail lamp socket to repair that was
a constant problem to run, and was very fragile.
- The existing mold had very small ejector pins pushing out thick, deep sections of the part
- They just could not keep the mold running at production speeds as it was always breaking
- We completely redesigned the mold, doing what some had said couldn't be done with the design
Our toolmakers then built a new mold which ran well consistently and eliminated the problem.
Case Study: One Stop Solution for Product Design - from Concept to
Market
Our salesman brought us a concept for a wireless,
remotely controlled auxiliary vehicle stop light which required product design
assistance, as well as the electronic design for the circuitry.
As part of our full-service philosophy, and
loving a challenge, we undertook the project:
- We designed the parts needed, including a light magnifying lens and the circuitry
- Designed and built the prototype tooling
- Designed the packaging
- Molded the parts
- Assembled the product
- Packaged the units
- Assisted with market testing
For a quote or more information about how we can help your project, call 765-457-1166, or send us an email, or submit this short form:
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