Customer Input
Collect drawings, 3D/2D files, material requirements, finish requirements, annual volume, delivery cadence, inspection standards, packaging and assembly environment.
- Confirm material grade, thickness and tolerance requirements.
- Review dimensional tolerances, GD&T, key dimensions and critical-to-quality features.
- Clarify burr direction, cut edge quality, radii, flanges, draw depth and forming limits.
- Confirm surface requirements such as cleaning, anti-rust, electroplating, powder coating, spray painting, brushing, sandblasting, anodizing, e-coating, laser marking, grinding, polishing, mirror finish, silk screen printing, pad printing and UV printing.
- Confirm whether welding, riveting, tapping, heat treatment or assembly is required.
- Use annual demand to choose tooling direction: single-operation die, compound die, progressive die or transfer die.
RFQ input checklistDrawing packageInitial risk questions
Engineering Review and DFM
Run drawing review and stamping manufacturability analysis before quoting or committing to tooling.
- Evaluate whether the part can be stamped and formed reliably.
- Identify drawing changes needed for manufacturability.
- Assess springback, cracking, wrinkling, burr and surface appearance risks.
- Define process options such as blanking, piercing, bending, drawing, restriking, trimming and forming.
- Estimate tooling concept, tool life, lead time and project risk level.
DFM commentsProcess conceptRisk listQuote and lead-time basis
Quotation and Project Kickoff
Confirm commercial scope and create the internal project package before samples or tooling begin.
- Confirm part price, tooling cost, sample cost, lead time, payment terms and acceptance standards.
- Create project schedule, BOM and manufacturing route.
- Prepare initial control plan, inspection plan and tooling development plan.
QuotationProject planBOMInitial control planTooling development plan
Sample Plan Confirmation
Choose a sample route that matches part complexity, validation purpose and stamping risk.
- Laser cutting plus bending for simple sheet metal parts.
- CNC, wire EDM or prototype machining for structural verification.
- Soft tooling or simple dies when samples need to be close to real stamping conditions.
- Local tool trials to validate high-risk draw, flange or springback areas.
Sample routePrototype planHigh-risk validation method
Sample Manufacturing and Internal Inspection
Make samples and complete supplier-side checks before sending parts to the customer.
- Inspect all dimensions or key dimensions according to the sample plan.
- Check material certificate, surface appearance, burr height and cut section quality.
- Run assembly verification, functional tests and required finish tests.
- Surface tests may include salt spray, adhesion and coating thickness checks.
SamplesSample inspection reportMaterial reportIssue listImprovement proposal
Customer Validation and Drawing Freeze
The customer validates assembly, function, appearance and reliability before production tooling is released.
- Validation result may be pass, conditional pass with minor changes, or fail with drawing/sample revision.
- Freeze the drawing version before production tooling to reduce rework risk.
- Keep sample feedback tied to drawing revision and acceptance criteria.
Customer approval notesFrozen drawing revisionOpen issue closure
Pre-Production Tooling Review
Confirm the final tooling plan after sample approval and before formal production die manufacturing.
- Confirm latest drawing revision, tool structure, tool steel, expected tool life and press tonnage.
- Review feeding method, scrap discharge method, gauge plan and key dimension control method.
- Define tool acceptance standards before cutting tool steel.
- For automotive or high-requirement customers, align APQP, DFMEA, PFMEA, control plan, MSA and PPAP expectations.
Tooling review recordGauge planTool acceptance standardAPQP/PPAP requirement list
Tool Design and Manufacturing
Design, manufacture, heat treat, assemble and prepare the die for press trial.
- Complete tool design and tool design review.
- Purchase tool steel and standard tooling components.
- Machine plates, punches, dies and inserts.
- Perform heat treatment, fitting, assembly and press setup.
Tool designMachined tooling partsAssembled dieTrial readiness
Tool Trial and Tuning
Run T0, T1, T2 and additional trials until forming, dimension and appearance are stable.
- T0 checks whether the part can be formed.
- T1 corrects dimensions, burr, springback and appearance issues.
- T2 verifies near-production stability.
- Continue T3 or T4 if the part still needs tooling correction.
- Each trial should include a trial report, dimensional report, issue photos, repair plan and next-trial schedule.
Tool trial reportDimensional reportIssue photosTool modification plan
Pilot Run
Run a small batch, often 300, 500 or 1000 pieces depending on the part, to validate production readiness.
- Check dimensional stability, continuous press capability and cycle time.
- Monitor burr change, material utilization, yield and operator work instructions.
- Validate inspection frequency and packaging method.
- Confirm packaging and transportation do not deform or scratch the parts.
Pilot run reportYield dataPackaging validationUpdated work instructions
Customer Approval and PPAP
Submit production samples and approval documents before formal mass production.
- Common documents include dimensional report, material report, surface treatment report and samples.
- High-requirement projects may include control plan, process flow chart, PFMEA, gauge report, CPK/stability data, packaging specification and PPAP documents.
- Approval scope should match customer requirements instead of adding unnecessary paperwork.
Approved production samplesDimensional reportControl planPPAP package if required
Mass Production and Continuous Quality Control
Run production according to controlled documents and keep quality feedback tied to tooling and process improvement.
- Execute SOP work instructions, first-piece inspection, patrol inspection and last-piece inspection.
- Maintain tool checks, equipment checks, lot traceability and nonconforming product isolation.
- Use daily production reports, outgoing inspection, customer complaint handling and continuous improvement.
Mass production partsInspection recordsTraceability recordsCorrective actions