From Ground Zero to Full Production

Description
To optimize supply chain efficiency and reduce transport costs for a key customer in Germany, Molding Academy took on the challenge of building an injection molding factory from the ground up, right next door. The goal was clear: establish a fully operational facility and meet contractual production requirements within 14 months. With an innovative and integrity-driven approach, we delivered—and then some.

Our strategy unfolded seamlessly:

• Team Building: We recruited and trained a skilled team from scratch, fostering a culture of engagement and accountability through open communication and Gemba walks—bringing leadership to the shop floor.
• Quality Systems: We designed and implemented ISO 9001 and IATF 16949 quality management systems, ensuring compliance with automotive and industry standards. Both were audited and certified, reflecting our commitment to excellence.
• Equipment Setup: We installed and validated state-of-the-art injection molding equipment, fine-tuning every detail to guarantee reliability and output.
• Lean Environment: By embedding Lean principles, we created an efficient, employee-centric workplace that maximized productivity while maintaining a safe and healthy environment.

The result: In just 14 months, the factory was fully operational, meeting all customer requirements ahead of schedule. The ISO 9001 and IATF 16949 systems passed audits with flying colors, and the facility achieved a remarkable 35% overcapacity—positioning it for future growth. This startup success highlights Molding Academy’s ability to deliver impactful, innovative solutions from a blank slate. Ready to build your next success story? Request a consultation today.