How a $30,000 “savings” became a $120,000 rebuild—and what every engineer should know about long strand glass fiber before committing to tooling. Glass fiber warpage injection molding The part came
Author: ChrisM
When “industry standard” pricing doesn’t make sense, sometimes the best solution is a napkin sketch and a talented local tool maker. “We’re going through pins every shift.” That’s the message
The 4-Month Paint Rack Problem We Solved With a 3D Printer (And the $500K Disaster We Avoided) We had a problem that looked impossible to solve. An automotive component—four feet
The Maintenance Worker Who Saved Us $2 Million (And Why We Almost Didn’t Listen) “Ya know, if ya did internal manifold it would fit.” The words came up over the
My boss dropped a complicated fuel loading project on my desk and asked for a project scope document. Not a rough outline—a comprehensive scope that would go to all stakeholders,
We were facing a capacity crisis. A new program was coming in, our injection resource planning showed we were running at 90% capacity, and we needed more machines. Fast.
The mold sat in our tool room for three months before anyone had the courage to scrap it. Three hundred and twenty-seven thousand dollars of hardened steel, precision-machined and
The Design Stage Health Check: 9 Questions That Predict Launch Failure I can spot a doomed project three months before the panic sets in. After 35 years
Plastic Injection Molding Offshore The $60,000 Mold That Cost $300,000 (And How to Offshore Right) I’d been brought on as their in-house project engineer specifically to manage launches like this
*The most expensive project failures aren’t caused by budget overruns or missed deadlines. They’re caused by the one thing most leaders overlook: the human cost of poor communication.*