The following five-step, streamlined process is indicative of the associated tasks involved.

1.    Disclosure of existing documentation
Production part print
Gauge/fixture print
BOM and routing sheet
Golden sample
Tool drawings and tool maintenance record
Molding and change-over instructions
NCMR history
Last 12 months process capability (control dimensions only)
Last GR&R for any inspection gauges or fixtures
Control plan

2.    Documentation conversion at new molder
Create BOM in appropriate MRP system
Measure golden samples
Create metrology instructions
Create inspection report
Create visual inspection report
Create work instructions
Set-up tool identification package
Set-up gauge identification and calibration schedule

3.    Tool evaluation
Document tool features
Document tool wear   
Measure gate sizes
Establish a preliminary preventative maintenance schedule

4.    Validation sample
Create visual set-up instructions
Create process window sheet
Document process related issues
Document tooling related issues
Measure samples (one part/cavity)
Run a short Production Part Approval Process (PPAP) run to confirm capability

5.    Qualification process
Qualification documentation record sheet
Process Failure Effect Mode Analysis (PFEMA)—by group
Control plan—by group
Process flow—by group
Part print
Insert print (if applicable)
Print acceptance form (PAF)
First article inspection (FAI)
Capability index (control dimensions only)
Gauge Repeatability and Reproducibility (GR&R; automotive only)
Tool evaluation
Material certification
Warrant

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