Process Development

Manufacturing Process Development That Scales

Getting a design right is only half the job — it has to be manufacturable at volume. Spot On Engineering develops and refines manufacturing processes across molding, forming, fabrication, and assembly. This process can be applied to any size business from small to large. In this image below, we were able to optimize the process in a $1.5 million small business.

Process flowchart showing the customer's overhauled workflow from sales inquiry through intake, production, delivery, and closing. — Our customer had an inconsistent process where steps were missed. We came in and overhauled the process and wrote quick, easy-to-understand workflows for each box on the attached chart. This resulted in a vast reduction in paperwork and a very consistent process. Physical paper was reduced 90% as it was scanned and placed in folders accessible by the whole team. Before and after pictures were maintained and everything moved through the system like clockwork. On the surface this seems obvious, but most small businesses have substantial gaps and will benefit greatly from this service.

Capabilities

Injection molding, injection blow-molding, and extrusion blow-molding process development
Small business process optimization
Sheet metal fabrication, hard tooling, and progressive die processes
Product assembly and testing process setup
High-volume injection mold development and automation integration
Lean Six Sigma-based process problem solving

Case studies

Case study

Clarifying Product Definition

A client needed to upgrade an existing product line, but aesthetic requirements and configurations hadn't been established.

Spot On Engineering proposed multiple concepts to help the client visually select design elements, using conceptual renderings to drive discussion and solidify a design direction — before committing to process and tooling.

Case study

Large-Volume Production Programs

Developed and managed manufacturing processes for dozens of consumer products from concept through mass production, supporting production volumes up to 500 million units annually.

Included high-volume injection molds, automation, and manufacturing pilot runs.

Have a project in mind?

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