As a leading manufacturer of custom injection molded components for two decades, Laszeray Technology has provided a broad array of quality products and value-added services to clients across many industries—aerospace, commercial, medical, military, and others.
Our product manufacturing method is a multi-stage process that involves the participation of several in-house departments managed by our expert staff. The complete product manufacturing process can vary according to the client’s individual needs; nonetheless, it may be informative to walk through a single case study as a way of providing specific examples about the procedures used by the Laszeray team in solving problems.
With that goal in mind, let’s explore a recent case where a client approached Laszeray with a production target that had a fast-approaching deadline.
The client was a well-established company that operates a comprehensive manufacturing and distribution network responsible for supplying more than 6,000 products to professional builders, contractors, engineers, and do-it-yourself customers around the world. They had an existing relationship with Laszeray, having turned to us in the past for help in procuring tooling for plastic parts.
For that project, Laszeray managed the production of the tooling by bringing the process in house. We sampled, revised, prototyped, and finalized the tooling. We then oversaw the first production run in order to get the product to market on schedule. Once their pipeline was full, we transferred the tool to their production facility, where they could manufacture it themselves.
The success of this endeavor inspired the company to reach out to us again on a later date when they needed a full turnkey solution for a home improvement product that could be sold at a retail DIY store. They needed a business partner that could handle procurement for metal, plastic, hardware, and other materials; provide assembly and packaging services; produce a retail-ready product; and, finally, ship it directly to their distribution centers.
The client had already developed a rough prototype, as well as detailed product specifications. However, the product was significantly more complex than any in their portfolio at the time, and they needed to get it into distribution centers in just four months’ time. They asked Laszeray to help them meet this tight deadline.
How did Laszeray tackle this challenge? The first step was to determine the best materials for the client’s specifications. Unfortunately, it soon became clear that the best materials for the job weren’t available as off-the-shelf products. We turned to outside manufacturers that were able to develop new resins for the project.
We then analyzed the client’s prototype. Together, we found that we were able to reduce the number of parts the product contained—for example, we replaced several O-rings with overmolded parts that could be manufactured with no assembly required. These adjustments both improved the product’s performance and made it easier to manufacture.
Laszeray reached out to the client’s engineering team on a regular basis to create an ongoing line of communication between the two companies. Our respective teams met at least once a week—either in person, via conference call, or WebEx—to discuss issues and potential solutions. Whenever a new prototype was created, we sent it to the client’s team for reviewing and testing. There was a lot of back-and-forth communication, involving many prototype iterations, before a final product design was approved by the client.
Due to the four-month project deadline, it became necessary to adopt creative solutions at certain points. For example, we had to source some components from domestic suppliers because we could not obtain them in time from overseas suppliers. The tooling process—generally one of the longest portions of any injection molding project—had to be commenced very early on. This forced us to make changes on the fly as needed. We also needed to create tooling for the retail packages, such as a blister card and a shipping box, and update them several times during the process.
While Laszeray supervised the project management details for the manufacturing of the product, the client handled the details of the overall launch to its customer base.
By the end of the manufacturing process, Laszeray had drawn upon several of its standard services:
- Design & Engineering
- Custom Injection Mold Tool Design & Manufacturing
- Custom Injection Molding
- Rapid Prototyping
- Secondary Finishing
- Value-Added Services
Because of Laszeray’s expertise in engineering, our global network of suppliers, our collaborative process, and our value-added services, we were able to deliver a full turnkey solution: a high-performing product in full retail packaging, delivered to the client, and ready to be sent to their distribution centers without their ever touching the product. The project concluded within budget and on time.
The client reported satisfaction with the final product; in fact, they have already committed to several future projects with Laszeray as their manufacturing partner. We have agreed to provide preventative maintenance on their in-house tooling, support for their in-house molding facility, and additional services as a supplier for overflow manufacturing.
The client will continue to rely on Laszeray as a partner for new projects that require tooling. Laszeray will manage all aspects of tool design and production, prototyping, and initial production runs to fill their pipeline. This allows the client to bring these tools in-house after all bugs have been worked out and on their own timeframe to minimize disruption.
Please explore our site for more information on the variety of services offered by Laszeray Technology. Feel free to contact us for more information.