Injection Moulding - Our Service Unit 13 - 15 Roughmoor Enterprise Centre, Roughmoor Industrial Estate, Williton, Somerset, Ta4 4at 01984632090

www.penhalequantock.co.uk

[email protected]

About Us Penhale Quantock Limited are a precision injection moulding company based in Somerset, England with over 30 years experience serving a range of industries including medical, agricultural, M.O.D and electrical. We provide a service covering the spectrum of production processes from inexpensive vacuum formed prototypes through to full injection moulding, as well as sub-assembly service.

We are able to injection mould thermoplastics from 1g to 1000g in a variety of materials from polycarbonate, nylon, rubber and many more. We have the capability to do insert moulding, post moulding and assembly operations in-house. Our experienced staff, some of which have been with the company for over 30 years, specialise in sample runs and getting the best results for our customers. We have a close relationship with a range of engineering experts to ensure we can produce the highest quality mouldings in the most cost effective and efficient way. We as a company excell in new tool runs, modifications and sample mouldings. Penhale Quantock works closely with our customers to ensure they have a full understanding of the process and value their input to help us achieve the best results.

Quality Quality remains the most essential element of our companies philosophy. Here at Penhale Quantock we are always looking at new ways to improve the quality of both our products and services. We believe the best way to achieve this is to have a close working relationship with our customers to determine their requirements, and look to develop ways to meet them. We have established procedures throughout the company, reviewed on a regular basis, to ensure all aspects of our business are up to standard. This commitment to quality has enabled us to proudly mould here in the UK for 30 years.

Bespoke Operating Procedures Ensuring our mouldings meet customer requirements is an essential aspect of our Quality Policy. We work alongside our customers to create bespoke standard operating procedures for ALL our products. These are available to hand during production and we believe this attention to detail significantly reduces the risk of mistakes. This process also ensures we have as much information from our customers about the standards required. Our staff are trained to have a full understanding of these procedures before being allowed to work on the product.

(Example taken from our Arena IP65 SOP)

2) Once the inserts have been correctly inserted, ensure any excess flash is removed from the edges of the moulding. ** Be careful not to damage the moulding itself, if this happens DO NOT pass the moulding Flashing occus most often on each of the ends

Objective Standards We believe its important to establish objective standards with our customers to provide a consistent level quality. This method ensures all parties are clear on the standards required and provides peace of mind. All criteria for acceptable mouldings are outlined, images are taken and the outcome signed off. The criteria may include: > > > >

Packaging requirements Extra work requested to improve quality Handling requirements Realistic product expectations

Objective Standards Customer:

(Example taken from our Horizon Dome standard)

PENHALE

Product: HORIZON DOME

Date: ../.../...

✓

x

When milling the sprue witness needs to even. If the moulding slips whilst drilling and the witness is not straight the moulding cannot be passed.

✓

x Ensure the sprue is drilled to the correct height.

x

Our inspection process ensures that your products are passed to comply with objective standards set by both parties. The criteria for these are included in the procedures which can be referenced during production when required. Ensure any added flash has been removed from the edge of the moulding. This has an effect on the diffuser fixing into the base, if any flash is left the moulding cannot be passed.

Material Management Good quality mouldings relies on excellent material handling, here at Penhale Quantock we have closely monitored systems in place to ensure our mouldings free of inclusions and contamination. We control the flow of material from its raw stage through to the finished product. Ways in which material can be affected include: Contamination This is the issue when it comes to material, the slightest foreign object within a batch can have an effect during production. We have measures in place to ensure this is avoided as much as possible. Our material is safely contained and our equipment is cleaned on a regular basis.

HOPPER

HOPPER

Material Grade Choosing a good quality material grade is essential: we take great care in choosing the most appropriate specification we require. Our supply chain team have over 30 years’ experience, enabling close relationships with key suppliers and ensuring our material remains at the standard we require. Production Preparation Before a product can go into production the material often needs to be prepared to ensure it performs to the standard expected. This can include for example the length of time it needs to be dried before use. We have preparation procedures in place to ensure all our material performs the way it should.

Step By Step Process We have outlined a step by step framework of how our process works. Whether your are new to moulding or own exitsting tooling we can help with you manufacturing requirements.

STAGE 1

Free Consultation

STAGE 2

Free Quotation

STAGE 3

Tool Production

STAGE 4

Sample Run

STAGE 5

What Now?

STAGE 1

Free Consultation

Stage one of the process is a free consultation with one of our moulding experts to discuss your ambitions and requirements for the project. This enables us to have a greater understanding of your desired outcome as early as possible, and helps us determine the ideal specifications moving forward. Topics covered during the consultation include: • • • •

Product outcome requirements / application Material requirements Design / CAD requirements Tooling requirements

A variety of factors can affect the final quality and the cost of your moulding. During the consultation these are discussed in detail to ensure a full understanding of the process. Identifying the correct specifications ensure’s the production process can run smoothly and minimise cost. We believe honesty is key and minimising risk for our customers is always at the forefront of our thinking. 01984632090

www.penhalequantock.co.uk

[email protected]

Choosing the correct material is one the most essential aspects in ensuring your moulding’s meet your desired product specifications. Different materials are more suited for certain environments and have unique characteristics, so it is important to choose the one best suited to your needs. If we take our Lighting Range as an example, we manufacture our enclosure’s in Polycarbonate. This material is ideal for the Lighting industry as it is UV stabilized, impact modified and is able to withstand high temperature’s caused by the LED’s.

01984632090

www.penhalequantock.co.uk

[email protected]

STAGE 2

Free Quotation

Once the moulding requirements have been confirmed a free quotation can be generated and issued. We ensure our customers are provided with a range of alternatives if required and advise on the best option with straight talking honestly.

If the drawings are already in existence it is at this stage we require them to generate a quotation for the Tool. An evaluation is done on them to ensure they are suitable for manufacturing. All information remains strictly confidential and we actively encourage both parties to sign a NDA for peace of mind.

STAGE 3

Tool Production Once all parties are happy the Tool can go into production, an estimated lead time will be advised on receipt of quotation. If the Tool is already in existence it may need to be brought in for inspection. This is to ensure it is suitable for production, if any alterations are needed you will be informed. If required a quotation for the amendments can be provided.

01984632090

www.penhalequantock.co.uk

[email protected]

STAGE 4

Sample Run

Upon receiving the tool a full inspection is carried out to ensure there are no issues and that it is ready for production. A report is generated outlining all the details for customer reference and our company records.

After the inspection has been carried out, and you are happy to proceed, the first trial run can be scheduled. During the trial we evaluate the procedure’s required for production to ensure they are as efficient as possible. To ensure a consistent high quality we work closely with our customer’s to generate our Standard Operating Procedure’s (SOP’S), which we have bespoked for all our products. These are kept to hand during production for reference when required. Customer input on our SOP’s also ensures we find the correct balance between added cost and desired outcome best suited for your circumstance. It may be for example that your require your mouldings to be indiviually wrapped or are happy for them to be boxed together, we aim to find a solution best for you.

Desired O

utcome Added Co st

Now the first off samples have been manufactured we invite our customers down to help us set objective standards for the mouldings and sign the samples off. Once these have been signed, and all parties are happy we are ready to schedule in your first production run.

01984632090

www.penhalequantock.co.uk

[email protected]

STAGE 5

What now?

Product Portfolio We issue all our customers a portfolio conatining all relevent information regarding their products. This ensure’s our customer’s have as much information as possible and enables us to update the document with reports and any potential updates moving forward. The document may include: • • • • • • • • •

Product Specifications Standard Operating Procedures Job Sheets Material Specification Non-disclosure agreement(s) Objective standards records Drawings Images Reports

Review After a series of production run’s we look to review the progress of the mouldings. This is important, especially in the early stages, to ensure the mouldings are meeting your product requirements. We understand that a change in the performance of your mouldings may be required to satisfy YOUR customer’s expectations once the product has gone to market. In many instances this may be resolved with a slight tweek in material grade or colour change.

01984632090

www.penhalequantock.co.uk

[email protected]