supply-chain-disruptions-srushty

5 Strategies To Mitigate Supply Chain Disruptions

Contract Manufacturing

The supply chain is the art of applying engineering intelligence to convert raw materials from suppliers into consumer products in a safe manner

What are the Challenges in supply chain management?

Supply chain challenges include material, Labour availability & pricing, lack of traceability, increased shipping cost, demand forecasting, and communication gaps.

Why do we need supply chain management?

The goal of supply chain management (SCM) is to improve efficiency, quality, productivity, and customer satisfaction. SCM involves activities such as procurement, management, and storage of raw materials, manufacturing, and the moving, delivery, and storage of finished goods.

Disruptions in SCM?

  • Manpower shortages: Labor shortages can limit the reliability and affect the seamless flow of supply.
  • Lack of demand forecast: Sudden spikes in demand can challenge businesses to meet increased customer expectations. 
  • Technology Advancement: Supply chain being a bigger network-operated process, needs technology advancement in process tracking, and planning. Lack of technology is a threat.
  • Logistics & Regulatory hurdles: Regulatory hurdles can cause supply chain disruptions. Government regulations may vary from country to country, making it difficult to manage the supply chain. When sourcing cheap materials from different countries, challenges in importing or exporting can lead to disruptions.
  • Pricing fluctuations: Pricing fluctuations can significantly impact supply chain stability. Factors such as changes in market demand, raw material costs, and economic conditions can lead to unpredictable price changes.

How to mitigate supply chain disruption?

1. Vendor Selection

The vendor selection process typically involves multiple stages of audits to assess the capabilities of potential suppliers. This may include evaluating their team strength, machine availability, in-house capacity, quality assurance (QA) and quality control (QC) processes, and warehouse capabilities.

Establishing a non-disclosure agreement (NDA) with vendors is essential to ensure the confidentiality of client assets and proprietary information.

2. Demand Forecasting

Organizations analyze long-term demand forecasts to assist in planning and inventory management. This analysis helps in making recommendations to buyers for preplanning and aligning supply with anticipated demand.

3. Pricing Strategies

To address pricing fluctuations, companies often negotiate long-term supply contracts with vendors. This approach can lead to more stable pricing and cost savings over time. Additionally, strategic investments in vendor partnerships can enhance process improvements and increase overall productivity.

4. Logistics Management

An effective logistics system involves partnerships with various transportation options, such as air and sea freight, allowing organizations to choose the best method based on lead time requirements.

Engaging subject matter experts (SMEs) can help navigate regulatory compliance and avoid delays related to logistics and shipping.

5. Technology Utilization

Implementing an ERP (Enterprise Resource Planning) system aids in project planning and real-time progress tracking, ensuring effective management of lead times.

Emphasizing design for manufacturability and conducting stage-wise quality inspections throughout the supply process can minimize the risk of product rejections and enhance overall supply chain efficiency.

AUTHOR

Saravanan Kottieswaran

Assistant Manager Manufacturing, Srushty Global Solutions

As a Mechanical Engineer with extensive expertise in Vendor management, metal fabrication, CNC machining, and injection molding, he brings a wealth of expertise in overseeing production processes, optimizing workflow efficiency, and ensuring high-quality output. His dedication to building strong client relationships and passion for innovation and continuous improvement in manufacturing techniques make them an invaluable asset to our team.

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Green Manufacturing- CNC and Sustainable Practices - Srushty CM

The Future of Green Manufacturing: CNC and Sustainable Practices

Contract Manufacturing

What is the future of green manufacturing?

In today’s rapidly advancing industrial landscape, the manufacturing process has undergone a significant transformation, particularly with the advent of computer numerical control (CNC) machining. This sophisticated method utilizes pre-programmed computer software to carry out intricate machining operations, significantly enhancing automation while minimizing human intervention. The result? Improved accuracy, reduced labor costs, and heightened safety in production. One of the most remarkable advantages of CNC machining is its versatility; it can be applied to a wide range of materials, including metals, plastics, ceramics, and composites, making it an invaluable asset in modern manufacturing.

As we navigate the complexities of contemporary manufacturing, the importance of green manufacturing cannot be overstated. This approach focuses on minimizing negative environmental impacts while conserving energy and natural resources. By optimizing energy use, manufacturers can operate more effectively, significantly cutting down on energy waste. Increasingly, industries are turning to renewable energy sources to mitigate their carbon footprint, signaling a vital shift toward sustainability.

Green Manufacturing for CNC! Why its needed?

The global manufacturing market is projected to soar from an estimated $748.2 billion in 2023 to $944.6 billion by 2030, with a compound annual growth rate (CAGR) of 3.4%. However, this growth comes with challenges. Traditional manufacturing processes often consume large amounts of energy, resulting in significant CO2 emissions and other pollutants. To combat these environmental concerns, manufacturers are adopting innovative techniques and improvements aimed at optimizing efficiency and energy consumption.

According to the U.S. Energy Information Administration (EIA), manufacturing facilities consume approximately 95.1 kilowatt-hours (kWh) of electricity and 536,500 British thermal units (Btu) of natural gas per square foot annually. It’s essential to recognize that these figures can vary significantly depending on the specific type of manufacturing operation.

This blog draws on research conducted by Mohsen Soori from the Department of Aeronautical Engineering at the University of Kyrenia, Kyrenia, highlighting the importance of sustainable practices in CNC machining.

To make CNC machining operations more sustainable, optimizing machining parameters is key. By fine-tuning cutting tool paths, manufacturers can reduce material waste and lower energy consumption. Investing in energy-efficient CNC machines further contributes to minimizing the ecological footprint of machining processes. Additionally, employing virtual simulations and analyses allows manufacturers to pinpoint areas where sustainable practices can be implemented, leading to reduced waste and enhanced efficiency.

Key strategies for enhancing energy efficiency in CNC machining includes are CNC machining parameters optimization, Cutting tool paths optimization, Process planning of CNC machining.

CNC Machining Parameters Optimization

1. Material Selection:

Choosing the right materials is fundamental to sustainability in machining. While steel and plastics are common choices, environmentally friendly alternatives like titanium, brass, and aluminum offer better sustainability profiles. Selecting materials that are not only efficient to machine but also have a lower environmental impact is essential for reducing the overall carbon footprint.

2. Cutting Parameters:

The selection of appropriate cutting parameters—such as cutting speed, feed rate, and depth of cut—can drastically affect both energy consumption and material waste. For instance, the optimal cutting speed varies depending on the material and the specific machining operation. By fine-tuning this speed, manufacturers can lower energy usage and minimize waste.

  • Cutting Speed: Optimizing cutting speed for the material being machined can lead to significant reductions in energy consumption.
  • Feed Rate: Adjusting the feed rate can decrease the amount of material removed, further minimizing waste.
  • Depth of Cut: Reducing the depth of cut not only conserves energy but also decreases material waste, making the process more sustainable.

3. Cutting Tool Selection:

The choice of cutting tools is another critical factor. Selecting durable and long-lasting tools can enhance the sustainability of the machining process. Tools designed with optimal material and geometry reduce wear and tear, leading to less waste and improved operational efficiency.

4. Lubrication and Cooling:

Using the right lubricants and coolants can play a significant role in enhancing machining sustainability. Proper lubrication reduces tool wear, improves surface finish, and lowers energy consumption, contributing to a more efficient machining process.

5. Waste Management:

Effective waste management is essential for a sustainable machining operation. Implementing recycling programs for metal chips and other waste materials can significantly reduce environmental impact, promoting a circular economy within the manufacturing sector.

6. Machine Maintenance:

Regular maintenance of CNC machines not only extends their lifespan but also enhances performance and reduces energy consumption. Well-maintained machines operate more efficiently, which can lead to lower energy costs and decreased need for replacements.The optimization of the turning process for sustainable machining is presented in the figure below.

Effective Process Planning for Sustainable CNC Machining with Green manufacturing

Process planning in CNC machining is a critical step that focuses on creating an efficient and sustainable manufacturing process. This involves designing machining operations that not only yield high-quality parts but also prioritize minimizing environmental impact, reducing waste, and optimizing resource utilization.

  1. Designing for Sustainability: A well-thought-out process plan considers sustainability at every stage. By selecting environmentally friendly materials and efficient machining methods, manufacturers can significantly lower their ecological footprint while still producing quality components.
  2. Waste Reduction: Effective process planning emphasizes strategies to minimize waste throughout the machining process. This includes optimizing cutting parameters, tool paths, and overall machining sequences to ensure that every movement is purposeful, thereby reducing scrap material.
  3. Resource Optimization: In sustainable CNC machining, resource utilization is key. Process planning should aim to maximize the use of energy and materials while maintaining or even enhancing productivity and product quality. This may involve incorporating advanced technologies, such as real-time monitoring systems, to ensure resources are used efficiently.
  4. Balancing Productivity and Quality: While the focus is on sustainability, it’s essential that process planning does not compromise productivity or product quality. By refining manufacturing processes, companies can achieve a balance that allows for high output without sacrificing the integrity of the finished product. The figure below illustrates the seamless integration of process planning and cutting parameter optimization in CNC machining. This approach highlights how aligning these two elements can enhance overall efficiency and sustainability in manufacturing.

Conclusion

CNC machining has become a cornerstone of modern manufacturing, automating the production of precision components essential for industries such as aerospace, automotive, and medical devices. Embracing sustainable CNC machining practices involves implementing efficient and eco-friendly processes that not only reduce environmental impact but also enhance operational efficiency.

By prioritizing sustainability, manufacturers can achieve significant benefits, including cost savings and improved competitiveness in an increasingly eco-conscious market. As industries evolve and the demand for sustainable practices grows, adopting sustainable CNC machining will be crucial for future success.

AUTHOR

Sriram P

Sales Development Representative, Srushty Global Solutions

Meet Sriram, a visionary Sales Development Representative in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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difference between 3 4 5-axis milling machine

What’s the difference between 3-axis, 4-axis & 5-axis milling machine?

Contract Manufacturing

What is CNC milling?

CNC milling is a process where a rotating cutting tool removes material from a block of raw material. The workpiece is securely fixed to a table that moves or rotates, allowing the tool to cut from various angles. Advanced CNC milling machines can have 5 or more axes, enabling them to create complex shapes or eliminate the need to move the workpiece to another machine.

What are the advantages of CNC milling?

  1. High Precision: CNC milling machines produce parts with exceptional accuracy and tight tolerances, making them ideal for detailed and complex designs.
  2. Consistency: Once programmed, CNC machines consistently produce identical parts, ensuring uniform quality and reducing variations across multiple pieces.
  3. Flexibility: CNC milling machines can easily switch between different tasks and designs by updating the program, allowing for quick adaptation to various production needs.

Here’s a simple breakdown of the differences between 3, 4, and 5-axis milling machines based on their motion capabilities:

3-Axis Milling Machine

This machine moves the cutting tool along three directions—X (left/right), Y (forward/backward), and Z (up/down). The tool remains fixed in terms of rotation, which limits the complexity of shapes it can produce.

3 axis-milling-machine
4-Axis Milling Machine

This adds an extra rotational axis, often referred to as the A-axis, allowing the workpiece to rotate 360° in the horizontal plane. This rotation lets the machine access different sides of the workpiece without needing to reposition it manually.

4-axis-milling-machine
5-Axis Milling Machine

This machine includes two additional rotational axes—B and C. It allows both the cutting tool and the workpiece to rotate, providing enhanced flexibility and precision. This capability enables the machine to handle more complex geometries and angles.

5-axis-milling-machine

AUTHOR

Sriram Parthiban

Business Analyst, Srushty Global Solutions

Meet Sriram, a visionary business analyst in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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low volume manufacturing

A Complete Guide to low volume manufacturing

Contract Manufacturing

Imagine a company is launching a new product but isn’t quite sure if it will work out. To avoid spending too much money on something that might not succeed, they start with low volume production. This means they make only a small number of products at first.

Low volume manufacturing has great benefits:

Less Risk: They don’t spend too much money upfront, so if the product needs changes or doesn’t work as planned, they don’t lose a lot.

Flexible Design: They can easily make changes to the product design based on feedback and tests without wasting resources.

Quick Feedback: They get feedback from customers faster and can improve the product quickly.

Cost-Efficient: It helps save money and resources, making it easier to manage finances while figuring out the best way to make the product.

In short, starting with low-volume production lets a company test its new idea with less risk and more flexibility.

The minimum level of production for low-volume manufacturing can vary by industry, product, and methods used. Typically, low-volume production ranges from a few units to several thousand, which is much less than high-volume production that can reach millions. Choosing low-volume manufacturing depends on factors like product demand, cost-effectiveness for small quantities, and the need for customization or quick market response.

To avoid spending too much money and resources upfront, they decide to start with low volume manufacturing. This means they’ll produce a small number of items first.

Here’s how different low volume manufacturing methods can help them make the best product efficiently:

Injection Molding

Injection molding involves creating a mold and injecting melted material into it to make precise parts. It’s great for producing small quantities of consistent and detailed components quickly.

CNC Machining

CNC machining uses a computer-controlled machine to carve out intricate parts from solid material. It provides high precision and is useful for making detailed components with exact specifications.

3D Printing (Additive Manufacturing)

3D printing builds objects layer by layer, like stacking blocks. It allows the company to create prototypes and test different designs quickly. Any needed adjustments can be made easily.

Urethane Casting

Urethane casting involves creating a mold and then pouring urethane material into it. It’s good for making flexible parts and is cost-effective for small runs of products.

Rapid Prototyping

Rapid prototyping quickly creates physical models from digital designs. This method helps the company test and refine designs quickly before moving to larger production.

Vacuum Casting

Vacuum casting uses a vacuum to fill molds with liquid material, producing high-quality parts with fine details. It’s suitable for low volume production and allows for easy changes to the design.

Laser Cutting and Engraving

Laser cutting and engraving use lasers to cut and etch materials with high precision. This method is perfect for creating detailed and complex shapes from various materials.

Die Casting

Die casting involves injecting molten metal into a mold under high pressure. It’s efficient for producing small quantities of metal parts with a high level of detail.

Extrusion

Extrusion pushes material through a shaped die to create long, consistent profiles. This method is useful for making continuous shapes and parts in low quantities.

Composite Fabrication

Composite fabrication involves combining materials, like fibers and resins, to create strong and lightweight parts. It’s ideal for parts that need to be both durable and light.

Silicon Molding

Silicon molding uses silicone rubber to create flexible molds for low volume production. It’s effective for making complex shapes and detailed parts.

By using these low volume manufacturing methods, the company can test and refine their product designs effectively, manage costs, and reduce risks. Each method offers unique advantages, making it easier to create high-quality products while keeping expenses in check.

Low-volume manufacturing is becoming more important in modern production because it offers benefits like customization, flexibility, and faster time-to-market. When considering low-volume production, you should think about factors like cost, time, quality, process type, and supplier choice.

Deciding between making products in-house or using contract manufacturing depends on your needs and resources.

Companies like Srushty Global Inc offer specialized low-volume manufacturing services, providing expert guidance and high-quality results.

As the manufacturing world changes, using different low-volume manufacturing methods can help businesses stay competitive and adaptable in fast-moving markets.

AUTHOR

Sriram Parthiban

Business Analyst, Srushty Global Solutions

Meet Sriram, a visionary business analyst in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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injection molding

Top 10 Injection Molding Companies in USA 2024

Contract Manufacturing

The US manufacturing sector is incredibly diverse, contributing a whopping $2.9trillion to the country’s GDP in 2023. That’s more than 10% of the entire economy! Plus, it’s a major employer, providing jobs to 13 million people, which makes up 8.3% of all US jobs.

On a similar note, the plastic injection molding machine market is also booming. In 2023, its market size was estimated at around $2.009 billion, and it’s expected to keep growing at a steady pace of 3.9% annually from 2024 to 2030. This growth is largely driven by increasing demand in various sectors such as healthcare, consumer goods, automotive, electronics, packaging, and more.

One of the key reasons behind this demand is the fact that plastic injection molding is a highly efficient and cost-effective way to produce plastic or elastomeric parts with high precision. It’s a process that ensures consistency and quality, which is essential in these industries.

If you’re in need of a reliable injection molding company to manufacture your products in the United States, you’ve come to the right place. We’ve done the hard work of analyzing hundreds of domestic injection molding manufacturers and have compiled a list of the top companies in the USA. These companies are worth checking out for your next project.

1. Srushty Global Inc

Founded Year: 2010

Office Location: Milpitas, California, USA

Business Type: plastic molding manufacturer

Top Services: Mold design and texturing, Plastic Injection Molding, Injection Molded Surface Finishes, Custom Plastic Fabrication.

Company Profile

Srushty Global Inc., your go-to partner for all things manufacturing, offers a seamless experience from start to finish. We pride ourselves on providing comprehensive solutions that cover every step of the process—from design and prototyping to full-scale production. With an in-house design team and a network of manufacturing partners across the globe, we ensure that your supply chain is smooth and efficient. Whether you’re looking to produce low-volume or prototype units, our customized manufacturing solutions are tailored to meet your unique needs. We’ve had the privilege of working with several Fortune 500 companies, bringing their visions to life with precision, speed, and reliability. At Srushty Global Inc., we make it easier for you to turn your ideas into reality.

2. Xometry Enterprise

Founded Year: 2015

Office Location: Washington DC Metro / Maryland, USA

Business Type: plastic molding manufacturer

Top Services: Plastic Injection Molding, Injection Molded Surface Finishes, Custom Plastic Fabrication

Company Profile 

Xometry offers high-quality plastic molding with a smooth supply chain. They have a strong network of manufacturing partners around the world. Whether you’re testing a new prototype or getting ready for full production, Xometry can help you grow faster.

3. Berry Global, Inc.

Founded Year: 2015

Office Location: Evansville, IN USA

Business Type: plastic molding manufacturer

Top Services: Plastic Injection Molding Manufacturing, Plastic Mold Building, OEM Plastic Molded Products Making, etc

Company Profile 

Berry Global is an injection molding company with a strong history of creating new products, focusing on customers, and growing strategically. Thanks to our team’s hard work, we’ve become a top provider of innovative solutions worldwide.

4. Proto Labs, Inc.

Founded Year: 1999

Office Location: 5540 Pioneer Creek Dr.,Maple Plain, MN 55359, United States of America

Business Type: plastic molding manufacturer

Top Services: Plastic Injection Molding,Liquid Silicone Rubber Molding, Overmolding and Insert Molding,etc

Company Profile 

Proto Labs, Inc., In 1999, Larry Lukis, a successful entrepreneur and computer enthusiast, started a company to speed up the process of making injection-molded plastic prototypes. He created complex software that connected with mills and presses, automating the traditional manufacturing process to save time.

5. Jabil Inc.

Founded Year: 1966

Office Location: Auburn Hills, Michigan, United States of America

Business Type: plastic molding manufacturer

Top Services: Plastic injection molded products for healthcare, packaging, smartphones, and cloud equipment to automotive and home appliances

Company Profile 

Jabil is a worldwide company that specializes in plastic molding. They use their wide range of experience, technical skills, design abilities, and supply chain knowledge to help top global brands succeed.

6. Bemis Manufacturing Company

Founded Year: 1987

Office Location: 300 Mill Street,P.O. Box 901,Sheboygan Falls, WI 53085-0901,USA

Business Type: plastic molding manufacturer

Top Services: Toilet seats, health care, precision parts injection molding manufacturing and custom injection molding

Company Profile 

Bemis Manufacturing Company, a family-owned business since 1901, is based in Sheboygan Falls, Wisconsin, U.S.A. We’ve grown into an international company making plastic injection molded products under our own brands and for others. We offer private-label products and parts for many industries, including consumer, commercial, medical, and industrial markets. With over 2,000 employees in five countries, we serve customers around the globe.

7. Fathom Digital Manufacturing

Founded Year: 2019

Office Location: 1050 Walnut Ridge Drive,Hartland, WI, USA

Business Type: plastic moulding manufacturer

Top Services: Plastic Injection Molding, Prototyping, Injection Mold Making

Company Profile 

Fathom is a top company for Additive Manufacturing (AM) and 3D printing, perfect for speeding up product development and production. They can quickly take your product from design to prototype to full production. Businesses from various industries use Fathom for both small and large-scale 3D printing. Their award-winning skills, speed, and quality make them one of the most trusted and innovative experts in manufacturing.

8. Plastikon Industries, Inc.

Founded Year: 1984

Office Location: 688 Sandoval Way,Hayward, CA 94544, United State of America

Business Type: plastic molding manufacturing

Top Services: plastic injection manufacturing,Injection Mold Design & Tooling,Plastic Engineering and Design

Company Profile 

Plastikon Healthcare, a subsidiary, was created to become a top global plastic and contract manufacturer. Today, Plastikon and Plastikon Healthcare offer award-winning services and are crucial to many successful companies in medical, automotive, and electronics industries. Using the latest technology and skilled employees, they’ve built a strong global reputation for exceeding customer expectations.

9. EVCO Plastics

Founded Year: 1964

Office Location: 121 EVCO Circle, DeForest, Wisconsin, USA

Business Type: plastic molding manufacturing

Top Services: plastic injection manufacturing, tooling and mold building, contract manufacturing

Company Profile 

Founded in 1964, EVCO Plastics has become a place where people work together to create innovative parts. The company’s success is thanks to the hard work and dedication of its employees. EVCO focuses on improving manufacturing processes by using the latest technology, robotics, and automation. These innovations help customers save costs and gain a competitive edge, which is the key to EVCO’s success.

10. Plastic Components, Inc.

Founded Year: 1969

Office Location: 9051 NW 97 Terrace, Miami, Florida 33178 USA

Business Type: plastic molding manufacturer

Top Services: PVC products injection molding manufacturing, plastic mold building

Company Profile 

Plastic Components is known for delivering top-quality products. We were the first PVC trim manufacturer to have our products tested and certified by an independent organization. Intertek Testing Services NA Ltd./Warnock Hersey reviewed our entire manufacturing process, from raw materials to shipping. This review is ongoing, and we’re proud that our products meet or exceed ASTM standards for strength, stability, and weather resistance. Our trims are listed with Intertek/ Warnock Hersey, ensuring excellent performance and compliance with ASTM standards.

AUTHOR

Sriram Parthiban

Business Analyst, Srushty Global Solutions

Meet Sriram, a visionary business analyst in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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tariff- blog

Facing Rising Import Tariff Rates? Here’s How You Can Mitigate Their Impact

Contract Manufacturing

In recent years, the landscape of international trade, particularly between the United States and China, has been significantly shaped by fluctuations in tariff policies. Starting in 2018, there has been a progressive increment in tariffs imposed on a wide array of Chinese goods, marking a notable shift in trade dynamics. In this post, let’s discuss in detail on the current state of tariffs, the reasons behind their imposition, and explores the broader implications for businesses and economies.

What is the Current Tariff Scenario? (2024 Update)

As of 2024, tariffs on Chinese imports have seen notable increases across various sectors:

Electric Vehicles: Tariffs jumped from 25% in 2018 to an unprecedented 100%.

Semiconductors and Solar Cells: These crucial tech components saw an increase from 25% in 2018 to 50%.

Medical Supplies like Syringes and Needles: Introduced at 0% and ramped up to 50%.

Steel and Aluminium Products: Increased from 7.5% in 2019 to 25%.

Lithium-ion EV Batteries and Other Parts: Rose from 7.5% in 2019 to 25% by 2024.

Personal Protective Equipment and Surgical Gloves: Adjusted from 7.5% to 25%.

Natural Graphite, Permanent Magnets, and Other Critical Minerals: These have all seen a tariff spike to 25% from 0%.

What is the Rationale Behind the Increases?

President Joe Biden’s recent decision to escalate tariffs on key Chinese products stems from a strategic intent to bolster the competitive edge of U.S. industries in global markets. This move also reflects a shift from the previous administration’s policies, which President Biden argued did not sufficiently boost U.S. exports. By implementing these tariffs, the administration aims to encourage fair competition rather than conflict, emphasizing investment in American industries as a backbone for sustainable economic growth.

What are the Strategies to Mitigate Tariff Impact?

Businesses affected by these tariffs are exploring various strategies to mitigate impact:

Relocating Supply Chains: Companies are considering moving manufacturing to countries that favor lower tariffs on their products.

Transshipments: Some are disguising the origin of products to bypass tariffs, though this involves significant legal risks.

Minimal Processing: Altering the product minimally in another country to change its country of origin designation.

Trade Zones and Bonded Warehousing: Utilizing designated zones that offer relief from immediate tariff burdens, allowing companies to defer payments until products are sold or transferred out of the zones.

What are the Broader Implications of Tariff Increases

While tariffs serve to protect domestic industries by making imported goods less competitive, they also raise government revenues. However, they can lead to increased costs for consumers and potential retaliatory measures from trading partners, affecting global supply chains and market dynamics.

Looking to Alternatives: India's Emerging Role

Amidst these shifts, India is emerging as an attractive manufacturing alternative, boasting demographic advantages, robust government initiatives, skilled workforce, and a growing domestic market. In fiscal year 2023, India’s manufacturing exports hit a record high of USD 447.46 billion, reflecting a competitive edge that could be further harnessed in light of shifting global manufacturing tides.

The increase in tariffs on Chinese imports marks a significant pivot in U.S. trade policy aimed at revitalizing domestic industries and reducing dependency on foreign manufacturing. While the move presents challenges, it also opens up avenues for alternative manufacturing hubs like India, setting the stage for a redefined global manufacturing landscape in the coming years. Businesses and policymakers alike must navigate these changes strategically to harness opportunities and mitigate risks in this evolving trade environment.

AUTHOR

Srushty Subject Matter Experts

Henry T. Bober

Subject Matter Expert, Srushty Global Solutions

Henry is a seasoned Mechanical Design Engineer with 40 years at Xerox Corporation, specializing in Product Development, Cost-Effective Design, and Technology Development. He holds degrees from West Virginia University and the University of Rochester and has 35 patents to his name. After retiring, he founded Fast Forward Engineering, consulting for clients like Xerox, Diebold, NCR, and Siemens Medical Products. Now a Subject Matter Expert at Srushty Global Solutions, Henry lives in Fairport, NY, with his wife Leslie and their pets. He enjoys Western-style horse riding, Japanese garden landscaping, woodworking, naval warfare history, and animal welfare advocacy.

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injectoion mold design

A Handy Guide to Minimize Injection Plastic Mold Complexity

Contract Manufacturing

In the rapidly evolving field of plastic manufacturing, companies constantly seek ways to streamline processes and reduce costs while maintaining high quality in their products.  A well-designed part does not need mold complexity to fix poor design choices.  In this blog let’s explore the principles of minimizing plastic part mold complexity, a critical factor in achieving efficient and cost-effective production.

The Principle of Simplicity in Mold Design

Taking steps to simplify part design at the conceptual stage can significantly reduce tooling lead times and lower tooling costs.  A streamlined design minimizes moving inserts, such as side pulls and lifters, within the mold.  This speeds up the manufacturing process and reduces the potential for errors, maintenance headaches such as wear and flash, and mechanical failures.

Avoiding Undercuts and Side Pulls

Undercuts, although sometimes necessary for complex shapes, can add significant costs and complications to mold design.  They require either clever design solutions or specialized mechanisms like side pulls and lifters, the latter not only increase the tool cost but can also impact the reliability and maintenance cost of the tooling. 

Tolerances and Detail Limitations

Specifying liberal tolerances and limiting details to functional necessities can greatly influence the ease of manufacturing and the lifecycle of the mold.  Over-specifying tolerances or unnecessary details can lead to increased costs and extend the tooling lead times due to the finer precision required in tool making.  Time equals cost!

Collaborative Design Process

Engaging in a dialogue with both the molder and toolmaker during the design phase is crucial to enabling success. Discussing aspects such as the gate type, quantity and location, the parting line locations, ejector pin quantity and locations, wall thickness, ribbing, coring and tolerances can lead to a design that is more conducive to ease of manufacturability. Part design will dictate the parting line.  Steps in the parting line will increase the machining required.  While a more planar parting is desirable, it may not be possible.  Mold Flow Analysis is always recommended.  Remember that uniform wall thickness, gentle transitions, no sharp corners and avoiding concentrated mass are essential to a good part, and therefore an efficient tool design.  Ribbing is important.  Not only do ribs add stiffness to the part, but they can also aid flow and damp vibration.  But be cautious about sink marks due to concentrated mass, obey the guidelines.  This cooperation ensures that all parties understand the requirements and constraints of the project, leading to better outcomes and fewer revisions.

Standardization and Tool Material Choices

Using standardized mold frames and components whenever possible can lead to significant reductions in both cost and time.  Additionally, selecting mold materials that are aligned with the projected production volumes can optimize tool life, cost and performance.  Ordering tool steel early in the process, based on a stable part design (i.e. size and shape), can decrease overall lead time as tool steel lead times can be significant.

Post-Tooling Considerations

For covers and appearance parts, an important tip is to avoid texturing the mold until all tool corrections have been completed. Textured walls require extra draft, at least 5o, to effectively eject parts without causing damage to the texture or the part itself.  It’s essential to ensure that the base mold is correct and all tooling reworks are completed before adding such final touches.

By adhering to these principles, manufacturers can significantly simplify the injection molding process. This not only reduces costs but also enhances the reliability and efficiency of production. In an industry where every second and penny counts, optimizing mold design and manufacturing processes can provide a substantial competitive edge. The examples below demonstrate some of the design choices that can reduce complexity in mold design, ultimately leading to a more streamlined, cost-effective and successful manufacturing operation.

AUTHOR

Srushty Subject Matter Experts

Henry T. Bober

Subject Matter Expert, Srushty Global Solutions

Henry is a seasoned Mechanical Design Engineer with 40 years at Xerox Corporation, specializing in Product Development, Cost-Effective Design, and Technology Development. He holds degrees from West Virginia University and the University of Rochester and has 35 patents to his name. After retiring, he founded Fast Forward Engineering, consulting for clients like Xerox, Diebold, NCR, and Siemens Medical Products. Now a Subject Matter Expert at Srushty Global Solutions, Henry lives in Fairport, NY, with his wife Leslie and their pets. He enjoys Western-style horse riding, Japanese garden landscaping, woodworking, naval warfare history, and animal welfare advocacy.

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suddenly applied load

What impact can suddenly applied load have on Structural Stress?

Contract Manufacturing

When designing and analyzing structural components, one critical aspect to consider is how loads are applied.  This seemingly straightforward element can significantly influence the stress experienced by a material.  The distinction between instantaneous and gradual load application plays a crucial role in determining whether static or dynamic stress analysis is required.

Instantaneous vs. Gradual Load Application

To ensure accurate stress analysis, it’s essential to understand that for this analysis to apply, the load must be applied instantaneously, with an impact velocity of zero. If the load is applied gradually—even if over just a few seconds—the static stress will develop throughout the material in equilibrium during the load application period.

But what exactly does "suddenly applied" mean?

A suddenly applied load refers to a force that is applied abruptly to a structure or material without prior warning or gradual increase. It differs from gradually applied loads, which allow the materials or structures to deform and adapt over time. This sudden application can lead to unique stress distributions and potentially dangerous failure modes if not properly understood and mitigated.

σSudden = 2 W / A

The Stress (σSudden) due to the “Suddenly Applied Load” in the Rod is MOMENTARILY

TWICE the Static Stress in the Rod due to the Weight (W)

When:

H = 0

VImpact = 0

When a load is applied suddenly, the material experiences a stress that is momentarily twice the static stress for the same load under gradual application conditions.

By utilizing the detailed mathematical descriptions, engineers can devise solutions that mitigate the adverse effects of these loads across different applications.

DISCUSSION AND AN EXAMPLE:

For this analysis to apply, the load application must be Instantaneous and the Impact Velocity must be zero.

If the load application is gradual, even if only over a few seconds, the Static Stress will develop in equilibrium throughout the material during the application period!

The term Suddenly Applied requires some definition, “A load is Suddenly Applied when the Load Application Time is Less than Half of the Fundamental Period, P, of the structural element “

Where P = 1/ωn

So, the Load Application Time must be, tApplication < 0.5 / ωn

Consider the example of a cam follower spring, the peak load is developed over the rise of the cam from low dwell to high dwell:

If the Rise occurs over 90o of camshaft rotation, for a camshaft rotating at 6000 rpm, the peak spring load application develops over 2.5 msec.

The speed of sound in steel is ≈ 16,000 ft/sec.  In 2.5 msec, the pressure wave would travel about 480”.

If the Natural Frequency of the spring is, ωn > 200 Hz, then the Loading is Suddenly Applied,

σSudden = 2 σStatic       

A Good Conservative Design Guideline!

For other rapidly applied loads, a Dynamic Stress Analysis might be in order, especially if the Impact Velocity ≠ 0, And the Dynamic Stress will definitely exceed the Static Stress!

AUTHOR

Srushty Subject Matter Experts

Henry T. Bober

Subject Matter Expert, Srushty Global Solutions

Henry is a seasoned Mechanical Design Engineer with 40 years at Xerox Corporation, specializing in Product Development, Cost-Effective Design, and Technology Development. He holds degrees from West Virginia University and the University of Rochester and has 35 patents to his name. After retiring, he founded Fast Forward Engineering, consulting for clients like Xerox, Diebold, NCR, and Siemens Medical Products. Now a Subject Matter Expert at Srushty Global Solutions, Henry lives in Fairport, NY, with his wife Leslie and their pets. He enjoys Western-style horse riding, Japanese garden landscaping, woodworking, naval warfare history, and animal welfare advocacy.

Keep Reading: Know More on 10 Reasons Why Outsourcing PCB Assembly Services Is Beneficial for You
aluminium flange blog

How to Achieve Cost-Effective Complex Aluminum Flange Bending

Contract Manufacturing

Lead time is crucial in any engineering solution. Reducing lead time will significantly accelerate the overarching NPD goals. In any engineering project, we aim to reduce lead time by sticking to the deadline. Sometimes, by applying a better solution, we can quicken the process. That’s when experience comes to play.

In every project I tackle, my primary aim is to minimize lead time without sacrificing quality. Sticking to deadlines is crucial, but it’s not just about meeting dates. Often, finding a more effective solution can help speed the process along. This is where deep experience and expertise really make a difference.

I’d like to share a personal experience from a contract manufacturing project I worked on for a semiconductor equipment manufacturer, which illustrates the significant impact of reducing lead times.

Application - Semiconductor Manufacturing machine

Complex flange bending in alumium 1100

The project involved complex flange bending in aluminum 1100, requiring a sheet thickness that is only 50% of the required bending length. This presented a significant challenge in the bending process

Specific challenges with Aluminum 1100

Aluminum 1100 Properties: This grade of aluminum is known for its excellent corrosion resistance, high ductility, and good formability. However, it is relatively soft and prone to work hardening, making precise control necessary

  • Sheet Thickness Relative to Bending Length: When the sheet thickness is only 50% of the required bending length, it introduces additional complexities:
  • Risk of Buckling: Thin sheets are more prone to buckling or warping during bending.
  • Control of Deformation: Ensuring uniform deformation across the bend can be challenging, as thinner materials may not distribute strain evenly.
  • Tooling Requirements: Special care is needed in selecting the correct tooling to apply uniform force across the bend without causing damage.

This project required bending a 2mm thick aluminum sheet into a 4mm bend, which was initially deemed impossible. Typically, a basic bending operation needs a bend radius at least 6 times the sheet thickness. Meeting these requirements would necessitate specialized tooling, increasing lead time and costing over $1400.

To avoid these additional costs and delays, we modified the design to use a bending length 6 times the sheet thickness. The excess length was then milled and polished using a CNC machine. This approach allowed us to complete the operation within budget and on schedule, delivering world-class quality without extended lead times.

AUTHOR

Saravanan Kottieswaran

Assistant Manager Manufacturing, Srushty Global Solutions

As a Mechanical Engineer with extensive expertise in Vendor management, metal fabrication, CNC machining, and injection molding, he brings a wealth of expertise in overseeing production processes, optimizing workflow efficiency, and ensuring high-quality output. His dedication to building strong client relationships and passion for innovation and continuous improvement in manufacturing techniques make them an invaluable asset to our team.

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Understanding the Benefits of CNC Machining for Your Next Project

7 Key Benefits of CNC Machining You Should Know

Contract Manufacturing

When it comes to manufacturing precision parts and components, CNC machining stands out as a leading technology for its accuracy, efficiency, and versatility. Computer Numerical Control (CNC) machining has revolutionized the manufacturing industry by offering a wide range of benefits that make it an ideal choice for various projects. In this blog, let’s look into the advantages of CNC machining and explore how it can take your next project to new heights.

Unparalleled Precision and Accuracy:

One of the most significant benefits of CNC machining is its ability to produce parts with unparalleled precision and accuracy. By using computer-controlled machines, it ensures that every component is crafted to exact specifications, eliminating the risk of human error. This level of precision is particularly crucial in industries where even the slightest deviation can have significant consequences, such as aerospace, automotive, and medical devices.

Enhanced Efficiency and Reduced Lead Times:

CNC machining is a highly efficient process that streamlines production, reducing lead times and costs. With the ability to operate around the clock without fatigue, CNC machines can produce large quantities of parts quickly and consistently. This increased efficiency enables businesses to meet tight deadlines and respond to changing market demands with agility.

Versatility Across Diverse Materials and Designs:

CNC machining can be applied to a wide range of materials, including metals, plastics, and composites. Whether you need to produce complex geometries, intricate designs, or large quantities of identical parts, it offers the flexibility to adapt to diverse project requirements.

Long-Term Cost Savings:

While the initial investment in CNC machinery may seem substantial, the long-term cost savings are significant. By reducing labor costs, minimizing material waste, and increasing production efficiency, it can help businesses reduce their overall manufacturing expenses. Additionally, the precision and accuracy of CNC machining reduce the need for costly reworks and repairs.

Real-Time Quality Control :

CNC machining enables real-time quality control, allowing for immediate detection and correction of any defects or deviations. This ensures that every part meets the highest standards of quality, reducing the risk of product failures and recalls.

Environmental Benefits:

The precision and efficiency of CNC machining also have environmental benefits. By minimizing material waste and reducing energy consumption, it contributes to a more sustainable manufacturing process. As businesses increasingly focus on reducing their environmental footprint, CNC machining offers a valuable solution.

Applications Across Various Industries:

The benefits of CNC machining are not limited to a single industry. From aerospace and automotive to medical devices and consumer electronics, CNC machining service is a versatile technology that can be applied to many sectors. Whether you’re producing complex aircraft components, precision medical implants, or high-performance automotive parts, CNC machining offers the precision, efficiency, and quality control you need.

CNC machining is a transformative technology that offers benefits for precision manufacturing. Its unparalleled precision, efficiency, versatility, and cost savings make it an ideal choice many industries. By leveraging CNC services, businesses can achieve superior quality, meet tight deadlines, reduce costs, and contribute to a more sustainable future.

AUTHOR

Sriram Parthiban

Business Analyst, Srushty Global Solutions

Meet Sriram, a visionary business analyst in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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