The Enclosure That Wouldn’t Sit Flat (Chennai/Oragadam → Chennai)

A US IoT brand had a plastic enclosure lid that always looked “tired”—little waves and sink marks. Assembly was slow, returns crept up, and photos on Amazon didn’t help.

We paired the buyer with a dependable molder in Chennai/Oragadam and ran a tight plan: a short DFM call with the factory’s toolroom, a clear sampling calendar (T1, T2), and a simple lay-flat go/no-go jig everyone agreed on. The factory made the mold adjustments; we kept them honest on dates, photos, and mid-run checks.

Four weeks later, the new samples sat flat, looked clean, and clicked together first time. Scrap fell from ~9% to ~2%, cycle time shortened, and lead time dropped by about 10 days because there was far less rework. Same part number—just a part the brand was finally proud to photograph.
Our role: shortlist the molder, run the plan, book independent QC, share evidence. Factory role: tweak tool and process.

From Pilot to Multi-Cavity Without the Drama (Chennai/Oragadam → Chennai)

Demand took off for a small consumer part. The buyer needed to move from a pilot “soft tool” to a hardened mold—and then run with multiple cavities—without losing cosmetic quality or schedule.

We set up a two-month ramp with an Oragadam molder: T1 samples, quick feedback loop, T2 confirmation, then a controlled step-up to multi-cavity. The factory handled the tooling; we kept the calendar, lined up first-article approvals, and checked that parts from each cavity looked and measured the same.

The first multi-cavity lot shipped on time. Variations stayed tight across cavities, first-pass yield crossed 99%, and on-time delivery hit ~97%. The brand got the volume it needed—without a single emergency airfreight.
Our role: supplier pick, ramp plan, first-article sign-offs, photo/measurement evidence. Factory role: build/qualify tools and run production.

“Can This Touch Food?”—Yes, First Time (Mumbai/Bhiwandi → Nhava Sheva)

A European homeware brand needed food-contact gaskets for cookware lids—and wanted the lab results before launch. No surprises after a container lands.

We matched them with a Mumbai-area supplier used to compliance work. The plan was simple: lock the resin/compound with the supplier, run early samples, do a small pre-screen locally, then send the official set to an accredited lab for LFGB/FDA testing. We kept everyone aligned on paperwork, sample IDs, and dates.

The reports came back pass, first time. The first PO shipped with test reports, declarations, and clear labeling guidance. Returns stayed low, and customer support stayed quiet—exactly what the brand wanted.
Our role: line up the right supplier and lab, schedule samples/tests, assemble the compliance pack. Factory role: make the parts and hold the spec.