Tooling Project Management
Quoting - Most new tooling projects start with a quotation or budgetary quote.  Our objective is to provide quotes within a few days unless the project is very complex. 

Planning - Our project plan database establishes the objectives, team members, financial goals, and milestone due dates.   We evaluate each project up front against a checklist of critical factors documenting problems and suggested improvements.  Requirements such as process, material, functional, quality and regulatory are reviewed and documented.  Failure Mode Effect Analysis (FMEA) is utilized and documented as an ongoing aspect of every project.  Project planning focuses on controlling and reducing variation.  Barriers to achieving optimums are identified.  Impact on infrastructure and resources is evaluated.

Design - Sapona uses Alibre Design Profession software to review and communicate 3 dimensional information with customers and suppliers.  Our degreed engineer on staff has years of experience in injection molding and tooling ready to provide design assistance.  Safety and proper use is evaluated.
Simulation - Mold flow and cool analysis can be applied to identify potential problems and evaluate options in advance.
Prototyping - Multiple options are available for developing prototypes depending on the complexity and uniqueness of the product.  SLA and SLS prototypes are sourced from 3D model files.  Single and multi-cavity pre-production molds can be constructed and sampled with quick lead times of 6 weeks or less.  These molds provide valuable empirical results that can be utilized to optimize the final production toolings.
Quality Planning - Customer supplied information is reviewed to determine internal controls and requirements.  Quality Plans are developed for each new item defining the inspection and testing, materials, packaging and labeling.  Samples are retained, and limit samples are marked for visual requirements when appropriate.  Required work instructions are verified.  Risk is evaluated.  A mold book is developed for each mold that has all pertinent information readily available to all personnel involved from the tool shop to the molding floor and includes standard process parameters, setup specifications, quality plans, drawings, work instructions, process records, maintenance records and logs.
Mold Sourcing - Sapona has several highly qualified mold building partners including two local shops capable of a wide range of types of production molds made in the USA.  When possible, we will also recommend tooling options with QC10 aluminum made in the USA.  Sapona also has developed several Asian sources for injection mold tooling that help to keep up-front tooling costs low for customers.  We have visited these shops and know their capabilities.  We have communicated our expectations in writing and through experience.  
Scientific Molding - A wide range of techniques are used to optimize processes and establish production capabilities.
Verification - During the sampling stage, various inspections and checks of process, dimensions, and functionality are performed by our quality personnel according to detailed drawings as appropriate.  Pre Production Approval Processes (PPAP) are implemented to meet customer requirements.
Validation - Processes are validated with capability studies, process optimization, written procedures and training.  Complete IQ-OQ-PQ (Installation/Operational/Performance Qualification) procedures are documented when required to address equipment calibration and maintenance, environmental conditions, process measures, key process variables and extremes, process capability, and process performance.  This applies particularly in cases where the outputs of a process cannot be directly measured.
Maintenance - Preventive maintenance is performed on a scheduled basis depending on shots run or date as appropriate.  Each mold gets special attention during each shift of production, and after each production run with routine cleaning and lubrication.  Mold cooling channels are protected with continuous chemical water treatment for corrosion, algae, and scale.  Low pressure mold safety set points are carefully set to prevent mold damage.
Continuous Improvement and Corrective Action:
Sapona is committed to continuously improving.  Systematic methods of project management and action plans are utilized to improve the systems and products.  The Plan-Do-Check-Act (PDCA) methods is used and focuses on control and reduction of variation.

CAD systems

• AutoCad Fusion 360
• Alibre
• We accept native Solidworks, ProE and Inventor Files, or .IGS, .STP files

In House Tool Shop Equipment List

• 1 Bridgeport Series 1 Mill with Accurite III
• 2 Harig 618W Grinders
• 1 Clausing C1440 Lathe
• 1 Miller Dynasty MIG/TIG Welder
• 1 Lincoln welder

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