Program at a glance

• Briefly describe the program timeline you're targeting from concept to intended production start.
• How many parts or unique part numbers does this tool need to produce at launch? Options: 1 part number, single-cavity, Multi-cavity single part, Multiple part numbers via swapping or inserts, Tool family with multiple cores, Other
• Who on your team will own tool approvals, and who signs the PPAP submission for this program? Options: Program launch manager, Tooling engineer, Product engineer, Quality engineer, Purchasing manager, Plant manager, Other
• Which APQP milestones for this program have already been scheduled and which remain tentative? Options: Concept review, DFM complete, Detailed design approval, Steel procurement, Tool tryout, PPAP submission, Production start
• Tell me about the most recent similar program your team launched, what went well and what surprised you.
• Estimate the target first-article date for this program and the buffer you expect for supplier tryout and iteration.
• Answer whether a supplier would be disqualified for missing your non-negotiable launch date by more than one week. Options: Yes, disqualify, Maybe, depending on mitigation, No, we would accept a delay

When the die slips, where the schedule breaks

• If a die arrives two weeks late on your program, which downstream milestone would you push or miss first and what cost would that create?
• Describe the direct commercial consequences your team reports when a tool delays production start on similar programs.
• How often have supplier timing issues required overtime, weekend launches, or paid air freight in your last three launches? Options: Almost every launch, Often, Occasionally, Rarely, Never
• Who notices schedule slippage first in your organization and how quickly does escalation typically occur?
• What contingency would have to be in place for you to accept a known two-week delay on critical tooling?
• Select the impacts you see as most critical when tooling milestones slip in your program. Options: Missed SOP or start of production, Increased inventory and carrying cost, Plant downtime or lost shifts, Expedited freight cost, Warranty or supplier liability risk, Program reputation with customer

Where first-try quality usually trips teams up

• Which part feature or tolerance on your drawings drives the most frequent tryout iterations, and why?
• Walk me through your last tryout, which adjustments were made, and which change forced a steel rework.
• On average in your recent programs, how many die iterations or part re-stamps occurred before PPAP clearance? Options: None, passed first try, 1 iteration, 2 iterations, 3 or more iterations, Varies widely by part
• List the simulation or DFM concerns your product engineers flag most often for these parts.
• If the tool fails to hit part dimensions at tryout, what acceptance condition would force you to pause production sign-off?
• Select the quality measures you consider non-negotiable at first parts on your program. Options: Critical GD&T dimensions, Surface finish and appearance spec, Material tensile or hardness confirmation, Dimensional stability over cycles, Cycle-to-cycle variation and scrap rate, Functional assembly fit

Engineering assumptions that will force rework

• Name an assumption in your current drawing package that, if incorrect, would require a tool redesign.
• Describe feeder, blanking, or material specifications in your program that are fixed and cannot be changed without formal approval.
• Count the number of suppliers or internal groups that must approve DFM recommendations before steel procurement begins. Options: 1, 2, 3, 4 or more, Unsure
• Do you require the supplier to deliver specific simulation outputs such as forming loads, springback data, or cooling maps? Options: Yes, all required, Some required, specified per feature, No, we accept summary reports, Unsure
• Identify the person or role on your engineering team who will validate DFM and simulation deliverables and confirm signoff authority. Options: Tooling engineer, Product engineer, Launch engineer, Quality engineer, Cross-functional review board
• Answer whether a supplier unable to provide the required simulation and DFM evidence within your schedule would cause you to pause procurement or accept a conditional scope. Options: Pause procurement, Accept conditional scope, Negotiate compressed delivery, Other

Other options you're weighing

• List the other vendors or internal teams you are actively considering to build this tooling, and say which capability would make you switch today.
• Why would you stay with the incumbent supplier or your internal tooling group instead of changing vendors for this program?
• Choose from the following factors that would have to be true about your current approach for you to keep it in place. Options: Price advantage, Proven SOP history with this tool type, Shorter internal lead time, Lower risk of rework, Existing warranty and spare parts support
• Has anyone on your team proposed handling the build entirely in-house and if so which department would own that work? Options: Yes, manufacturing engineering, Yes, tooling group, Yes, procurement, No, Unsure
• Name the remaining concern that would make you switch suppliers even if the incumbent matched price and schedule.
• From the list below pick all internal options you are evaluating for production tooling and tryout. Options: Use existing press capacity at plant, Tryout on supplier press then transfer, In-house CNC and EDM for tool work, Rapid tooling for initial validation, Capital investment in a new press, Other

What practical gates will block the build

• Identify the one deliverable in your program that, if missing, would stop steel procurement or tryout from starting.
• Are released drawings and revision-controlled models available for the full tool set required by your program? Options: Yes, fully released, Partially released, Not released, In change control
• Estimate the number of dedicated buyer and engineer FTEs you can assign to manage change requests during the tool build and tryout. Options: 0, 0.5 to 1, 1 to 2, More than 2, Unsure
• Does your plant have a press available for tryout on the dates you need and who controls scheduling at your site?
• Provide the regulatory, audit, or compliance approvals that must clear before tooling can be shipped to your plant.
• Choose whether lack of plant access or press time within your launch window would lead you to accept tryout at the supplier's facility or to delay production. Options: Accept supplier tryout, Delay production, Split tryout between sites, Decision depends on mitigation plan

What will make this a go or stop decision

• Point to the internal approval that could still block the award even if a supplier meets your delivery and first-article criteria.
• When would you expect to have commercial terms agreed and a purchase order approved for this tooling? Options: Immediately after tryout, Within 2 weeks of proposal, Within 4 to 8 weeks, Longer than 8 weeks, Unsure
• Would you be willing to accept conditional acceptance tied to PPAP timing, for example production sign-off after successful sample runs within four weeks? Options: Yes, Maybe with conditions, No
• Pick the documentation package you require before signing for tooling supply. Options: Released drawings and CAD models, FMEA and process flow diagram, Maintenance spares list and warranty terms, Tryout acceptance criteria and sample reports, All of the above
• Rank the top three risks you want the seller to own versus risks you will retain.
• By when can your team make a go or no-go decision if the supplier delivers a full scope proposal and a validated tryout schedule? Options: Within 1 week, 1 to 2 weeks, 3 to 4 weeks, More than 4 weeks

• Engineering Walkthrough — Tooling Concept & Tryout Plan

• Confirm the current state and its cost to your program
• You confirm the restated current state and the quantified cost to schedule and tryout iterations.
• Deliver a preliminary tooling concept package including CAD views, a DFM recommendations list, and simulation summary within 5 business days.
• Align on part requirements and critical quality targets
• You accept the presented tooling concept and the prioritized DFM changes as the path to first-try acceptance.
• Produce a risk matrix tying each identified forming/flow issue to mitigation actions, estimated impact on lead time, and expected tryout iterations.
• Present the manufacturable tooling concept and DFM recommendations
• Provide released part drawings, final material specs, target cycle rate, and GD&T callouts within 3 business days to finalize the concept.
• You agree the initial tryout plan, acceptance criteria, and next evidence required to proceed to detailed design and steel procurement.
• Confirm available tryout press dates and plant access windows for the next 60 days.
• Walk through simulation findings and prioritized risks
• Agree the initial tryout plan and acceptance criteria
• Validation checkpoint — confirm this maps to your needs

• Engineering Walkthrough — Tooling Concept & Tryout Plan
• Engineering Walkthrough Deck
• Engineering Walkthrough Brief

• meeting
• slides
• document

• Progressive stamping die design and build
• Transfer stamping die design and build
• Injection mold manufacture — single-cavity
• Injection mold manufacture — multi-cavity
• Die-cast tooling manufacture
• Checking fixture fabrication
• Assembly and weld fixture fabrication
• CNC machining of tool components
• EDM and precision erosion services
• Tool grinding and surface finishing
• Tool assembly, spotting, and set-up
• Press tryout and sample validation
• On-site die installation and first-run support
• GD&T inspection and PPAP sample submission
• Tool refurbishment and spare parts program

Progressive stamping die design and build

• Specify the revision level and file formats of the part geometry you will supply for die concept (for example released 2D drawings with GD&T, 3D STEP, native CAD). Options: Released 2D drawings with GD&T, 3D CAD export (STEP/IGES), Prototype prints only, No drawings yet
• Indicate the target cavity count and the run-rate requirement at production (parts per minute and annual volume).
• Identify the blank material, gauge, and surface condition called out on the drawing (for example 1.0 mm DP600 with E-coated surface).
• Who on your program will provide APQP milestone dates and own DFM sign-off (name and role)?
• Confirm the forming limits and the three critical GD&T callouts that the first-off sample must meet. Options: Critical GD&T provided on released drawing, Tolerance bands to be defined during DFM, Critical features TBD

Transfer stamping die design and build

• List the sequence of forming stations expected for the transfer die based on your process flow (for example: pierce, form, trim, flange).
• Provide the press line configuration and maximum press tonnage available for tryout and production (press make/model optional).
• Indicate indexing method and required handling interfaces between stations (for example conveyor pick-and-place, robot transfer, or manual). Options: Robot transfer interface required, In-die transfer only, Manual handling between stations, Other
• Specify required scrap trim strategy and any in-die scrap separation or chute requirements.
• Name any secondary operations that must be integrated into the transfer die delivery (for example clinching, staking, or fastener insertion).

Injection mold manufacture — single-cavity

• Specify the polymer grade, melt index, and any glass or mineral fill called out on the part print.
• Indicate required surface finish and texture references from the drawing or surface map file. Options: Polished to Ra spec on drawing, Textured per supplied sample, No surface spec provided
• Identify gate location preference and any hot-runner requirements shown on the tooling concept or toolability notes. Options: Cold runner, Hot runner, Valve gate, Undecided
• Provide cycle time target and expected shot weight or grams per shot for production rate calculations.
• State the required mold cooling scheme constraints from your thermal simulation or part design (for example conformal cooling, straight-drilled channels). Options: Conformal cooling required, Standard drilled channels, Cooling TBD during design

Injection mold manufacture — multi-cavity

• Specify intended cavity layout, balanced runner requirements, and expected cavitation per mold plate.
• Indicate how you will validate cavity-to-cavity balance (for example cavity flow test, pressure sensors, shot-weight mapping). Options: Cavity flow test, Shot-weight mapping, Pressure sensor logging, Undecided
• Identify any family mold constraints such as differing wall thicknesses or multicavity part families that affect gate design.
• Provide acceptable part-to-part dimensional tolerance spread across cavities for critical features called out on the 2D drawing.
• List planned hot-runner vendor interface requirements or preferred hot-runner control protocols.

Die-cast tooling manufacture

• Specify alloy and casting process (for example aluminum high-pressure die-cast using A380) and any part wall-thickness constraints from casting simulation.
• Indicate required vents, die cooling water connections, and part ejection strategy referenced in the die manufacturing notes.
• Identify expected cycle time and shot sleeve/plunger specifications used for machine selection.
• Provide required die life expectation in shots before rebuild or refurbishment is required. Options: <100k shots, 100k-500k shots, 500k-1M shots, >1M shots
• State any post-cast machining datums or fixture references that must be held to mating assemblies during tool build.

Checking fixture fabrication

• Describe the inspection workflow the fixture must support (for example CMM probing, manual gage check, optical scan). Options: CMM probing, Manual go/no-go gages, Optical/vision check, Other
• Provide the list of critical dimensions or GD&T features that the checking fixture must measure or locate.
• Indicate whether the fixture must include modular locators, datum targets, or kinematic mounts to match the production tooling datums. Options: Modular locators required, Fixed datums only, Kinematic mounts required, Undecided
• Specify required inspection throughput (parts per hour) and sample frequency for routine checks.
• List any measurement standards or lab accreditation references you require such as ISO/IEC 17025 calibration of CMM probes.

Assembly and weld fixture fabrication

• State the assembly sequence and cycle time per assembly that the fixture must support.
• Identify weld types, weld locations, and any fixture clamps or tooling required to guarantee fit-up to the assembly print.
• Provide allowable part-to-part stack-up for fastener hole locations that the fixture must hold during assembly.
• Which operator ergonomics or safety standards must the fixture meet (for example reach envelope, lockout/tagout clearances)?
• List required consumables or wear items to be supplied with the fixture (for example locator pins, clamp pads, weld shields).

CNC machining of tool components

• Provide the bill of materials (BOM) items expected to be machined and the required tolerances for each machined surface.
• Specify preferred tool steel grades or hardness targets for machined components called out on the tooling BOM. Options: P20, H13, Other specified grade, No preference
• Indicate surface finish targets for machined faces and whether post-process plating or hardening is required. Options: Surface finish per drawing (Ra), Nitriding required, Plating required, No additional finishes
• Identify any lead-time critical machined parts that must be prioritized during steel procurement.
• Which machine tolerances and inspection methods should be used for serial machining runs (for example in-process probing, first-article CMM)?

EDM and precision erosion services

• Specify the EDM features required (sink, wire, micro-EDM) and the dimensional tolerances they must achieve.
• Indicate target electrode materials and expected wear allowances for long-run erosion operations.
• Identify hardness or material conditions (surface-hardened layers) that will affect EDM parameters.
• Provide expected delivery lead times for EDM-produced components and any critical path dates.
• State the required surface integrity and recast layer limits after EDM in accordance with your drawing notes.

Tool grinding and surface finishing

• Specify grinding tolerances and surface roughness (Ra) for die faces and lubricant contact areas.
• Indicate whether polishing, texturing, or chrome plating is required for any tool surfaces per part finish callouts. Options: Polish to mirror, Texture per sample, Chrome plating, No finish required
• Identify inspection criteria you require after finishing (for example comparator sample, profilometer measurement, visual rating).
• Provide the maximum permitted subsurface damage or grinding burn thresholds documented on the tooling specification.
• List scheduled maintenance finishing intervals you expect for long-run tools (for example regrind after X hits).

Tool assembly, spotting, and set-up

• Provide the assembly checklist items you expect completed before first press spotting (for example die tryout checklist, lubrication, shimming, safety guards).
• Indicate the required press fit tolerances and die shoe interface dimensions used for set-up on the production press.
• Name the responsible owner from your team for acceptance of machine set-up and who will sign the set-up completion record.
• Specify the spare component list that must ship with the assembled tool (for example punches, springs, shear blades, locator pins).
• What evidence will validate tool set-up is complete on the press (for example signed set-up checklist, first-run dimension report, trial batch)? Options: Signed set-up checklist, First-off CMM report within tolerance, Trial batch dimensional report

Press tryout and sample validation

• Provide your target tryout window and the number of sample shots you expect during initial press trials.
• Indicate whether tryout will occur on the tool builder's press or on your production press and provide press tonnage and stroke rate. Options: Tool builder's press, Customer production press, Both
• Identify the tryout team members who will attend and their roles for die corrections and disposition decisions.
• Specify the SPC (statistical process control) or measurement plan to be used during tryout for critical features.
• What are the tryout acceptance criteria that will confirm sample parts meet GD&T and surface finish before shipment? Options: All critical GD&T within tolerance on first-off CMM, Surface finish per drawing and no functional rework required, Statistical sample within control limits

• Tooling Purchase Agreement
• Statement of Work (SOW) — Tooling & Services
• Order Confirmation / Purchase Order Acknowledgement
• Payment Schedule & Milestones
• Acceptance & PPAP Criteria Addendum
• Warranty, Spares & Refurbishment Agreement
• Change Order & Engineering Change Notice (ECN) Procedure

• Go-live Health Check (weeks 1-4)
• First Production Measurement (weeks 4-10)
• 90-Day Production Performance Review
• Quarterly Production Support and Warranty Review

• Schedule any approved refurbishment work and provide a work intake with scope and expected downtime window.
• Decide whether any tools meet the documented triggers for refurbishment or redesign per the thresholds recorded in Tooling Scope & Deliverables.
• Agree on the timeframe and owner for any escalated corrective actions to be completed before the next quarterly review.
• Publish a closure log for all warranty and corrective modification requests showing evidence and resolution dates.
• If refurbishment is triggered, document the refurbishment scope, estimated lead time, and spare parts required.
• For escalated items, produce an escalation packet with failure evidence, proposed corrective design action, and target delivery date.
• Open warranty and service log review
• Reduce open warranty or refurbishment requests and shorten average time to close corrective actions compared to the previous quarter.
• Agree a prioritized list of spares and refurbishment activities with target procurement or start dates.
• Document contingency measures for any high-risk tools or processes to avoid unplanned downtime.
• Publish the quarter's warranty and refurbishment trend report and an updated open-item tracker.
• Place orders for agreed critical spare components and record expected delivery dates.
• Re-confirm scope, deliverables, and owners
• Installation and commissioning checklist items are confirmed complete or have documented remediation actions with target dates.
• Open defects that block production are identified and documented with remediation tasks and dates.
• Document all open defects with a description, severity, and target resolution date.
• Provide a short report of first-run sample discrepancies and recommended containment actions for production continuity.
• Schedule required on-site support visits or remote troubleshooting sessions and record the planned dates.
• Present production run data vs targets
• Determine whether first-pass yield at production rate (%) and tool uptime at production rate (%) meet the targets recorded in Tooling Scope & Deliverables.
• Agree a prioritized list of corrective modifications and warranty actions with target completion dates.
• Document the measurement sources and frequency for ongoing monitoring until the 90-day review.
• Produce a remediation plan listing each corrective action, expected effect on yield or uptime, and target completion date.
• Create a short data packet showing how first-pass yield and uptime were measured and where the raw data is stored.
• Open warranty or service requests for items that meet warranty criteria and note required evidence for claim processing.
• Restate targets and acceptance context
• Confirm which remediation and warranty items are closed and which require escalation with new timelines.
• Trend analysis for yield, uptime, and service closure
• Root cause diagnosis for metric gaps
• Deployment and commissioning validation
• Present 90-day aggregated metrics
• Prioritize enhancements, spares, and refurbishment work
• Remediation and warranty closure audit
• Prioritize corrective modifications and warranty items
• Initial parts and tryout observations
• Agree remediation timeline to next checkpoint
• Open defects and immediate remediation plan
• Refurbishment and redesign decision criteria
• Operational risks and contingency planning