Mention has already been made concerning the absolute necessity of having a definite objective at the outset. Vague ideas on the subject are hazardous. Assuming then, that a plant layout has been determined and the floor space calculated for the presses to be used, the production problem must now be approached. If orders have not been actually taken or promised, requirements have at least been anticipated and estimates must have been made on the items to be sold. Knowledge as to whether the customer’s needs are five thou sand or a million units over a given period naturally affects the price he is quoted. This is true in the submission of any quotation due to the economy that can be realized in continuous production.
The settingup and dismantling of a plastic injection mold for small quantity requirements is expensive and a long run is usually the most desirable. Aside from these features, there is another factor which influences the newcomer in the plastic injection molds making field, for with sufficient large quantity orders he is then in a better position to purchase his powder at a lower price. Buying molding plastic material, whether it be the phenol or urea type, is an expensive proposition when purchased in single drum lots. Even now, some of the smaller users are paying as high as twenty five percent more for molding powders than the larger plants. If this differential can be obliterated, one great disadvantage will have been overcome. But it will be impossible to enjoy the minimum price unless a sufficient amount of business is first obtained to warrant a large powder order.
So, rather than having one or two large accounts on the books, a much better condition is to gain the business of a half dozen or more. Before it is possible, however, to accept large orders it is essential that reasonable production is promised. Large quantity orders usually entail rapid deliveries and a definite schedule must be submitted to the customer. In order to live up to these promises, either a large multiple cavity die must be made or two smaller molds for producing the same article. In the past, general practice has leaned towards the larger mold, but for many reasons two dies are more practical. Such practice insures the molder, to a certain degree, against complete loss of production in the event that repairs have to be made on the die, or if the larger injection molding machines are unavailable. In other words, if something happens to one of two molds, repairs can be made while the other mold continues to run. Production is crippled, to be sure, but not completely stopped as would be the case with one large mold.