If you want to find a quality injection molding factory in China, you need to complete the entire journey of the inquiry, risk management, proofing, the entire process of the molding, manufacturing, and delivery to mass production.

China has been dominating the injection molding manufacturing industry for the past ten years. Realistically, \”China injection molding supplier\” seems easy to find, however, the quote \”really reliable and suitable supplier for you\” is an arduous task.

This guide was created from the industry, internal supply chain management, mold making technical specifications, and years of procurement.

This guide has 50+ selection criteria, 33 risk points, a full decision tree, templates, and industry case studies from the USA and Europe.

This guide will allow you to:

• Tell the good from the bad for suppliers
• Tell if the offering is genuine or perhaps a ploy to get you in a low pricing trap
• Pick the best supplier group based on your expected product from them and quantity
• Steer clear of the mold, the resource fraud, mass production, and other regular industry fails
• Us custom templates to run audits on suppliers based on a set checklist
• Create an available \”Chinese injection molding supplier selection system\” for your company.

Let us begin.

Part 1 — Why Choosing the Right China Injection Molding Supplier Is So Difficult

Selecting a China-based injection molding supplier should be simple. You compare price, look at a few samples, ask a friend, check Alibaba, and place the order.

But reality is very different.

In the actual operation of China’s supply chain, “choosing the right injection molding supplier” is the most critical step in determining the success rate, yield, delivery time, and final profit of the project. This section will explain in depth:

• Why do companies always fall into traps?
• Why do seemingly established suppliers also overturn?
• Why the lowest-priced option could become the most expensive version?
• Why overseas buyers are more likely to be misled by factories than local buyers
• Why “injection molding difficulty” is grossly underestimated

Let’s start with the most common questions.

1. The most common pain points encountered by global companies when looking for Chinese injection molding suppliers

You have most likely experienced each of the following：

1.1 never see the real factory capabilities (serious information asymmetry)

Most Chinese injection molding factories will not say:

• “We don’t have the experience to make products of your level”
• “Our mold capabilities are not enough”
• “The reason we quote a low price is because we don’t know how high the accuracy you require”
• “We have never made medical-grade transparent parts”
• “We cannot control the tolerance to±0.02mm”

Instead they will say:：

“We can do. No problem. Very easy.”

WHY?

Because in Chinese factory culture:

• Will not reject customers easily
• Afraid of losing orders
• Confidence or blind optimism
• I think the problem can be solved later
• Unsure of the customer’s true requirements

The end result is: you simply can’t tell from the first round of communication whether the factory really understands your product.

1.2 Overseas buyers don’t understand the real difference in “mold quality”

Many foreign companies think that “a mold is a mold.”

But in reality:

Many failure cases occur when: Buyers need L3 ,but the factory does it according to L1 .Because you don’t understand injection molding industry. The factory will not tell you the real difference,maybe they didn’t know at all.

You thought you made a very good deal, but in fact you bought a “cheap but worthless mold.”

1.3 The factory will not tell you: your product is actually “difficult to make”

Do you think this is just a simple plastic piece?
Maybe the factory is thinking:

• “The mold needs extra sliders or lifters due to this undercuts or side holes.”
• “The wall thickness is so thin that the section will be hard to fill”
• “The thick section parts will deform without enough cooling water channels.”
• “The tolerance is so strict, we can’t do it”
• “This product is defective in design”

but they won’t say

Because:

• afraid you won’t place an order at my factory
• We can solve it later
• Maybe really don’t know how difficult it is (more dangerous)

Eventually you will find:

• Can’t make a sample
• Made but so many problems
• Many NG
• cannot be assembled
• Actual cost 2–3 times higher than quoted price

1.4 Delivery delays and quality disasters due to “low price trap”

This is the most common pitfall for foreign buyers:

• Quotes are 30–50% lower
• You thought you earned it In fact, the factory simply cannot make high-quality molds with this budget. So they change low grade steel and use low quality plastic material.

The result is:

• Mold life is 1/5 from the original quotation.
• Batch failed rate 10–40%
• Slow Production (poor cooling design)
• Modifications are done every month
• Every mass production need to be reworked
• The project will never be stable

Eventually you find：

The lowest offer is often the most expensive one

1.5 constantly “misunderstood” dut to Remote communication

What Chinese injection molding factories are good at is：

• CAD drawing
• Traditional processing requirements
• Simple structural requirements

However, overseas customer requirements may include：

• International testing standards
• UL certification
• UV resistance
• Assembly tolerance stack-up
• Structural requirements for future expansion
• Supply chain risk end user experience

These are almost always ignored in the first round of communication

lead to：

• wrong-design modification- mold modification-1-4 months delay.
• Or the product never meet its original standards.

1.6 We did not realize what the actual situation was until 3 months later of working with the Chinese factory.

Nearly all buyers have the following experience：

• Month 1: Everything ok
• Month 2: Sample little problem
• Month 3: You have your design problem.

You do not know until half-way through the project:

• the factory machinery outdated.
• The number of technicians is vert few.
• You are not their VIP.
• They have too many low-priced orders.
• No professional project manager .
• Nobody knows much of your parts.
• The part is subcontracted to other plants (you do not know).

Now it is too late for you to change factories.

2. It is not merely a factory you want, but the “appropriate factory.“

What is not actually understood by the overseas companies is that：

China’s injection molding factories fall into 8 entirely distinct categories based on capability, scale, and positioning.Choosing the wrong type = an 80% probability of project failure.

Below are the most common types found in the market:

Major Disasters for Choosing the Wrong Supplier

Each of the following issues could cost your extra 3–9 months or even fail.

3.1 Mold Design Errors

Manifestations:

• couldn’t release from mold
• Uneven cooling
• Very thin walls
• Excessively prominent ejector pin marks
• Shrinkage and deformation

Case Study:
An American company designed a complex structural part. To offer a lower quote, the factory skipped mold flow analysis. The resulting mold proved completely unworkable, failing even after five revisions.

3.2 Wrong Material

Issues:

• recycled material
• lower-grade material
• No material brand
• Unstable coloring

Ultimate Consequences:

• Brittle fractures
• Finger print marks
• Discoloration
• Aging

3.3 Mold Cost-Cutting

Includes:

• Reduced cooling channels
• Reduced ejector pins
• Non-compliant steel grades
• No heat treatment
• Low-cost hot runner systems

Resulting in:

• Shortened mold life
• Slow cycle speed
• High defect rates
• Increased mass production costs

3.4 Unstable Mass productoin Quality

Causes:

• Personal levels
• Outdated injection molding machines
• Non-standardized process parameters
• Poor raw material management

3.5 Inconsistent Quality Between Samples and Mass Production

Sample Production:

• New machines used
• Premium materials used
• Well Adjusted machines

Mass Production:

• Standard machines used
• Cheaper materials used
• Poorly adjusted machine

3.6 Suppliers Subcontract

Extremely Common:

• Insufficient in-house capacity
• Unable to handle complex structures
• Outsources low-cost processing for you

The factory you see ≠ the actual production facility.

3.7 Assembly Tolerance Issues

You assume the injection molding factory understands:

• Cumulative tolerances (stack-up)
• Assembly clearances
• Different material shrinkage
• Post-molding dimension change

But many factories lack this understanding entirely.

3.8 Lack of Project Management

Resulting in:

• Missed engineering drawings
• Unconfirmed tolerances
• Unconfirmed materials
• Unconfirmed structural details
• inaccurate delivery schedules

3.9 Poor Communication

Even basic instructions like:

• “Surface finish: MT11010”
• “Tolerance: ±0.05mm”
• “Requires food-grade material”

can be misinterpreted.

Summary: Chinese injection molding suppliers must be evaluated in a systematic approach. Instead of simply basing it on price, samples and reviews offered by Google or Alibaba, your selection criterion should be:

• Technical competence Experience in molds
• Alignment of the complexity of the structure
• Understanding of materials
• Project management skills
• Communication skills in engineering
• Quality control competence
• Transparency of the factory
• Potential of a sustainable partnership.

Part 2 — Evaluate China Injection Molding Suppliers

In the last part we discussed the pitfalls, low-price trap and why foreign purchasers would fall into trouble when selecting the injection molding suppliers in China.

Next comes the most imperative section, which is to develop a scientific and reproducible supplier evaluation system. This would allow you to easily decide on the reliability of a factory without losing money due to errors and defects.

1. Setting up a Supplier Selecting Process.

The procurement project, being highly complex, must rely on a five-step approach:

1. Initial Screening

• Sources: Alibaba, trade shows, referrals, overseas supply chain networks
• Qualification Verification: Business license, ISO/TS certificates, major client case studies
• Eliminate Clearly Unviable Suppliers

2. Capability Assessment

• Technical Capability: DFM (Design for Manufacturing), mold flow analysis, mold design, material handling
• Equipment Capability: Injection molding machine tonnage, CNC, EDM, CMM (Coordinate Measuring Machine)
• Quality System: IQC (Incoming Quality Control), IPQC (In-Process Quality Control), FQC (Final Quality Control), OQC (Outgoing Quality Control), FAI (First Article Inspection), CPK (Process Capability Index)

3. Quotation Evaluation

• Breakdown of Mold Costs
• Breakdown of Injection Unit Prices
• Hidden Costs: Material markups, rework, logistics, communication delays
• Avoid Low-Price Traps

4. Sample Validation

• T1 Sample (Initial Version)
• T2 Sample (Revised After Feedback)
• Mass Production Trial (Small Batch Run)

5. Long-term Cooperation Potential Assessment

• Factory Response Speed
• Engineer Communication Skills
• Delivery Accuracy Rate
• Project Management Capability
• Risk Control Ability
• Willingness for Sustainable Cooperation

2. Initial Screening: How to Quickly Determine Factory Viability

Key Indicators:

Tip：The goal of the initial screening is not to find the perfect factory but to eliminate obviously unfeasible factories and narrow it down to 10–15 candidates.

3. Technical Capability Evaluation

3.1 Engineering Capabilities

• DFM Reports: Does the company present Design for Manufacturing (DFM) reports?
• Mold Flow Analysis: Does it carry out Moldflow Analysis?
• Optimization Skills: Do they have the ability to optimize wall thickness, draft angles, and parting lines?
• Complex Mold Experience: Do they deal with complex molds, hot runners, and slides?
• Material Knowledge: Do they know the properties of different plastics (e.g., PP, ABS, PC, PA66, POM)?
• Material Alternatives: Is it possible that they suggest alternative materials?

3.2 Mold Capabilities

• Steel Check: Can the grade of steel and the source be checked?
• Lifespan of Mold: Is the lifespan of the mold within the production requirements?
• Machining Precision: What is the precision and capability of EDM/CNC machining?
• Warranty Terms: What are the terms of warranty for the molds?
• Design Rationality: Does the design of hot runners, ejector pins, and venting make sense?
• Delivery Control: Does the mold delivery time make sense?

3.3 Equipment Capabilities

• Injection Machine Compatibility: Does the tonnage of the injection machine fit into the structural dimensions?
• Multi-Cavity Control: What is the issue with hot runner and multi-cavity mold control?
• Finishing Capabilities: What does it have in terms of polishing, spraying, silk screening, and assembly capabilities?
• Inspection Equipment: Does it have CMM (Coordinate Measuring Machine) and optical inspection equipment?
• Management Systems: How high is the MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) management?

Recommendation

Video Assessment: The best way to assess is to carry out a video inspection and demonstration of the injection molding process of the factory. It is not enough to use pictures or brochures.

Quotation Evaluation: Visible Dissection and Escape Low-Pricing Traps

Quotation Breakdown Method

• Mold Cost = Steel + Mold base + CNC/EDM + design + assembly + profit.
• Unit Price = Material + Molding Cycle + Labor + Post Processing + Packaging + Defect rate Loss.

4.1 Hidden Costs

• Material Markup: This is used especially with transparent parts and engineering plastics.
• Mold Modification Fees: Extra expense would be paid on a change in the mold.
• Rework Costs: Costs to fix the mistakes.
• Logistics and Tariffs: Transport and custom fees.
• Communication Delays: Costs that are incurred due to a misconception or a problem in translation.

4.2 Avoiding Low-Price Traps

• Red flag: Quotations that are considerably less than those in the market (e.g., 30%) are dangerous.
• Quality Requirement: There could be some compromises in the mold steel or hot runner materials.
• Undercapacity of the Machine: A machine with inadequate power may result in more time-draining molding and increased variation of quality.
• Absence of Quality Control: No process of quality assurance will lead to high rates of rework.

Tip: When asking the suppliers to quote, always ask them to make a clear breakdown of quotation, such as specification of the steel grades, labor hours, and lifespan of the mold.

5. samples checking（T1 → T2 → Small Batch）

5.1 t1 Sample

• Dimensions: Verify that the molded parts meet the specified dimensions.
• Appearance: Assess the visual quality and finish of the parts.
• Shrinkage: Monitor any shrinkage that occurs during the cooling process.
• Warping: Check for any warping or distortion of the molded parts.

5.2 T2 sample

• Process: Modify the mold from the T1 sample checking result.
• Verification: check dimensions and functionality again.

5.3 Small Batch

• Confirm the stability of mass production.
• Defect rates
• Color accuracy
• Glossiness

Tip: Always conduct a small batch test of at least 50–200 pieces before mass production to ensure the factory’s ability to produce consistently.

6. Potential Long Term Collaboration.

Besides technical capabilities, the potential of long-term cooperation is also important. Evaluation and observation:

Tip: Collaborating on a long-term basis is better than low prices in the short-term.

7. Understanding Technical Documents

1. Moldflow Analysis Report

Key Focus :

• Weld lines
• Shrink marks
• Bubble locations
• Cooling uniformity

Purpose: Assess the mold design reasonablity

2. DFM Report (Design for Manufacturing)

Key Focus :

• Wall thickness
• Draft angles
• Parting line design
• Number of ejectors

Purpose: Evaluate production feasibility.

3. Sample Testing Report

Key Focus :

• Dimensional deviations
• Tolerances
• Material properties
• Surface finish
• Color

Purpose: Validate factory capabilities.

4. CMM Inspection Report (Coordinate Measuring Machine)

Key Focus :

• Critical dimensions
• Tolerance of mating holes

Purpose: Check mass production controllability.

8. Systematic Evaluation

Factory Questionnaire Example (Ready to Use)

• How many injection molding machines ? What is the clamping tonnage for each machine?
• What is your mold manufacturing capability? What types of steel do you use? What is the expected lifespan?
• Do you provide DFM or Moldflow analysis?
• Do you have IQC, IPQC, FQC, OQC, FAI, or CPK processes?
• What is the typical lead time for molds? How do you handle delays?
• Is there a limit on the number of sample modifications?
• Can you provide small batch trial production?
• Are you willing to sign an NDA?
• What are the terms regarding mold ownership contracts?
• Can you provide references or case studies from previous clients?

QC Inspection Checklist Example

• Appearance: Warping, bubbles, scratches
• Dimensions: Critical dimensions ± tolerances
• Materials: Color, glossiness, certifications
• Molds: Ejector marks, shrink marks, parting lines
• Batch Stability: Dimensions, weight, defect rates

Tip: By combining questionnaires and checklists, you can quickly compare multiple suppliers.

9. Scientific Supplier Evaluation Process

By implementing a scientific supplier evaluation process, you can:

Use structured criteria to identify and choose the supplier that best fits your specific needs and project requirements.

• Avoid Low-Price and Mold Traps

Prevent falling into the pitfalls of choosing suppliers solely based on low prices which may compromise quality.

• Validate Factory Technical Capabilities and Quality Systems

Ensure that the supplier has the necessary technical expertise and quality management systems in place to meet production requirements.

• Verify Mass Production Feasibility

Use small batch production runs to test and confirm that the supplier can meet your mass production needs effectively.

• Assess Long-Term Collaboration

Evaluate the supplier’s capability for long-term partnerships, including reliability, capacity, and willingness to adapt to changes.

• Select the Most Suitable Supplier

Use structured criteria to identify and choose the supplier that best fits your specific needs and project requirements.

Part 3 — Molding Cost Breakdown and Hidden Costs in China Injection Molding

In the previous sections, we talked about the problems with picking Chinese injection molding suppliers as well as how to methodically evaluate factories’ capabilities. Next, we move on to how to break down the costs of the molds and the costs related to injection molding, along with the hidden costs that are often disregarded. This will be essential to avoid price traps and the costs that come with having to redo the work with the additional time to be reimbursed.’

1. Breakdown of Mold Costs (Transparency)

Many overseas purchasers focus just on the total price of the molds without understanding the internal components, and it makes them susceptible to misleading low prices or unreasonable quotes from suppliers.

1.1 Main Components of Mold Costs

Note: Any quote that is more than 30% below the market price may indicate shortcuts, substandard materials, or overlooked critical steps.

1.2 Analysis of Mold Steel Types

Characteristics of different steel types:

Tip: Request the steel batch number from the factory and consider third-party testing if necessary.

2. 注塑单价拆解

注塑单价 = 材料成本 + 循环周期成本 + 人工 + 后处理 + 包装 + 返工率损耗

2.1 材料成本

• 常见材料价格差异大（ABS, PP, PC, PA66, POM, PC/ABS）
• 高性能工程塑料（PC/ABS，PA66 GF30+）价格是普通 PP 的 3–5 倍
• 注意色母或透明件颜料的额外费用

2.2 循环周期成本

• 包含注塑机电费、机器磨损、时间成本
• 复杂件（多滑块、热流道）周期长 → 单价高
• 模具设计不合理也会延长循环周期

2.3 人工成本

• 小工厂：$2–$5 / hr
• 中型工厂：$5–$10 / hr
• 高端工厂（精密件/光学件）：$10–$25 / hr

2.4 后处理成本

• 抛光、喷涂、丝印、镀膜、装配
• 小工厂可能省略或外包
• 高端客户需明确写入报价

2.5 包装成本

• 简单纸箱 vs 防静电托盘
• 定制包装 / 用户品牌包装需额外费用

2.6 返工率成本

• 不良品率 1–5% → 可接受
• 不良品率 10%+ → 成本直接翻倍
• QC 体系不完善的工厂 → 隐性返工成本高

3. 隐形成本分析

海外采购往往忽略以下几个隐形成本，导致实际总成本比报价高 30–100%：

Tip: 海外采购成本 = 报价 + 隐形成本。只有全面考虑才能判断性价比。

4. 可复制的供应商报价对比模板

建议用 三维评分法 进行供应商评估：

4.1 模板示例

评分标准：

• 0–3: 极差 / 不可接受
• 4–6: 一般 / 需小心
• 7–8: 良好 / 可合作
• 9–10: 优秀 / 优先选择

Tip: 评分法可快速筛掉低质量低性价比供应商，并对比隐形成本。

5. 案例分析：低价陷阱 vs 科学报价

案例 1：低价陷阱

• 报价：$1,500 模具 + $0.15 / 件
• 真实情况：偷钢材，回料，模具寿命低
• 结果：小批量 OK，但量产返工 20%+，总成本翻倍

案例 2：科学报价

• 报价：$2,500 模具 + $0.25 / 件
• 透明拆解，含材料、热流道、设计修改
• 结果：量产良率 99%，无需额外返工，总成本最低

结论：透明报价 + 小批量验证 + 技术能力匹配 = 最低总成本，而不是单纯追求低价。

Part 4 — Quality Control and Production Stability in China Injection Molding

在前几部分，我们讲了如何选择合适的中国注塑供应商，以及如何拆解报价和分析隐藏成本。
然而，即便供应商技术能力优秀，如果没有完整的 质量控制体系 (QC)，量产阶段仍可能出现严重问题。
本章节将详细解析如何通过 IQC → IPQC → FQC → OQC → FAI → CPK 等体系，确保零件稳定、高品质生产。

1. 为什么质量控制比供应商选择更关键

选择优秀工厂只是第一步，量产阶段仍存在几个风险：

• 样品良好，但量产批次波动大
• 原料批次差异导致尺寸、颜色或强度不稳定
• 工艺参数未标准化导致收缩或翘曲
• 操作人员经验差，导致外观缺陷
• 模具磨损导致关键尺寸超差

结论：量产稳定性 = 技术能力 + QC 流程 + 标准化操作 + 材料管理 + 模具维护

2. 中国注塑厂常用 QC 流程

中国工厂通常采用以下流程（英文缩写常用于国际采购）：

2.1 IQC — 来料检验

目标：确保原材料和外购件符合要求。

检查内容：

• 材料牌号、供应商、批号
• 颜色、光泽、物理性能
• 加纤料或助剂比例
• 材料尺寸、颗粒完整性
• 必要时化学成分或物理测试

Tip: 不良原料会导致批量失控，IQC 是防止量产失败的第一道防线。

2.2 IPQC — 过程检验

目标：生产过程中发现问题，防止批量报废。

关键环节：

• 每批 1–5 件关键尺寸检测
• 注塑机参数监控：温度、压力、保压、冷却时间
• 模具温度及循环检测
• 关键工序工人操作规范检查
• 外观检查：翘曲、缩痕、气泡

Tip: IPQC 可以在量产初期就发现问题，避免大规模返工。

2.3 FQC — 成品检验

目标：出厂前保证每件产品符合要求。

内容：

• 外观：划痕、气泡、翘曲
• 尺寸：CMM 或卡尺测量关键尺寸
• 功能测试：装配、耐力、扭矩等
• 包装检查：数量、标签、静电防护

Tip: FQC 不只是抽检，而应覆盖关键尺寸 100%，确保客户收到的产品一致性。

2.4 OQC — 出货检验

目标：出货前再次确认产品与客户要求一致。

检查点：

• 装箱数量
• 产品外观、功能
• 包装完整性
• 出货文件（COC, MSDS, Packing List, Test Report）

Tip: OQC 是最后一道防线，防止物流中出现因包装或文件错误的客户投诉。

2.5 FAI — 首件检验

目标：确认模具、工艺和量产参数是否正确。

• 对照图纸或 3D 文件
• 关键尺寸全部测量
• 检查模具寿命与公差
• 样品需通过客户签字确认

Tip: FAI 不做，量产容易翻车。很多低价工厂直接跳过首件检验，这是高风险行为。

2.6 CPK — 工艺能力指数

目标：衡量量产过程是否稳定，控制关键尺寸公差。

• 常用指标：Cp、Cpk
• 适用场景：孔位、厚度、装配尺寸
• 通过统计分析判定工艺是否需要改进
• 高端客户（汽车、医疗、光学）必做

Tip: 没有 CPK 数据的工厂，量产尺寸波动无法控制。

3. 如何验证工厂 QC 能力

1. 要求 QC 流程文件
   • 检查是否有 SOP（Standard Operating Procedure）
   • 每个环节是否有人负责
2. 实地 / 视频验厂
   • 看 IQC 样品检测
   • 看 IPQC 抽检
   • 检查 FQC 记录
   • 观察 OQC 包装流程
3. 要求 FAI 报告和小批量数据
   • 确认首件检验报告真实、完整
   • 核查批量数据是否有统计记录
4. 试产监控
   • 小批量生产 50–200 pcs
   • 每批抽检 5–10% 或关键尺寸 100%
   • 验证返工率与标准偏差

Tip: 实地验厂 + 数据验证是确保工厂量产稳定性的黄金组合。

4. 样品到量产的完整执行流程

1. 样品阶段
   • T1：验证工厂可成型
   • T2：修改后的样品验证
   • 样品确认签字
2. 小批量试产
   • 50–200 pcs
   • 全面 IQC / IPQC / FQC 检查
   • 确认 CPK 和良率
3. 量产前准备
   • 确认模具维护状态
   • 关键工序操作员培训
   • 生产参数标准化（温度、压力、冷却时间、顶针速度）
   • 材料批次确认
4. 量产阶段
   • 每批抽检关键尺寸
   • FQC 全检
   • OQC 出货前最后复核
   • QC 数据记录归档
5. 长期质量监控
   • 模具使用寿命计划
   • 工艺参数更新
   • 材料供应商验证
   • 客户反馈收集

Tip: 没有标准化流程，即便技术能力再强，也会在量产阶段翻车。

5. 实用工具与模板

• QC 检查表（尺寸、外观、功能）
• 首件检验模板（FAI 表格）
• 批量稳定性记录表（Cpk 计算）
• 返工/不良率分析表

通过这些模板，你可以量化工厂表现，而不仅凭感觉或口头承诺。

6. 总结 Part 4

质量控制与量产稳定性决定最终产品能否顺利上市：

1. IQC / IPQC / FQC / OQC / FAI / CPK 全流程缺一不可
2. 小批量试产是验证量产能力的关键
3. 数据化监控和记录可长期降低风险
4. 模具维护与材料管理同样重要
5. 工厂的 QC 能力比报价低价更关键

Part 5 — Long-Term Collaboration & Supplier Management in China Injection Molding

在前四部分，我们详细讲解了：

1. 为什么选择中国供应商需要谨慎（Part 1）
2. 如何系统化评估供应商能力（Part 2）
3. 模具成本、注塑单价与隐藏成本分析（Part 3）
4. QC 流程与量产稳定性（Part 4）

现在的重点是：如何把优秀供应商转化为长期可靠合作伙伴，形成持续竞争力。

1. 长期合作的价值

选择供应商不仅是一次性交易，更是一种长期战略：

• 降低采购成本：长期合作可谈更优价格和付款条款
• 保证质量稳定性：长期熟悉你的产品和工艺，返工率低
• 提高响应速度：紧急订单、模具改造、特殊材料可快速处理
• 降低供应链风险：建立信任关系，防止关键零件断货
• 促进创新：供应商参与设计优化、材料选择、工艺改进

Tip: 成本最低不等于总成本最低，长期合作价值往往高于单次低价。

2. 供应商管理关键要素

2.1 合同与协议管理

1. NDA（保密协议）
   • 模具设计、配方、工艺文件必须保密
   • 保护你的知识产权
2. 模具归属条款
   • 明确模具所有权
   • 模具维护、折旧、停产处理方式
3. 交付条款（FOB / CIF / DDP）
   • 确认物流责任
   • 避免隐藏运费争议
4. 质量条款
   • 合同中明确 QC 标准、首件检验要求
   • 不良率、返工成本、赔偿条款
5. 付款条款
   • 分阶段付款：T0（签订）、T1（模具完成）、量产前
   • 避免一次性全额支付，降低风险

2.2 KPI 与绩效管理

长期合作需量化供应商表现：

Tip: 定期（季度或半年）对供应商进行 KPI 评估，并将结果与价格、合同调整挂钩。

2.3 风险分担机制

• 模具维护与损坏
  • 约定工厂负责模具自然磨损之外的重大损坏
  • 你提供关键材料或工艺指导
• 原料波动
  • 协议约定材料升级、替代方案
  • 对材料价格浮动进行合理分摊
• 紧急订单
  • 设置加急费或优先生产条款
  • 明确双方责任

Tip: 风险分担机制让双方利益绑定，提高长期合作稳定性。

3. 海外采购与供应商沟通最佳实践

3.1 项目管理

• 指定项目经理（PM）负责全流程
• PM 负责沟通、跟踪、文档归档
• 每个关键节点（设计、模具、样品、量产）设立里程碑

3.2 工厂关系维护

• 定期视频或实地会议
• 参与模具评审、样品评审
• 给予供应商及时反馈和表扬
• 长期合作奖励机制：优先订单、批量折扣

3.3 工艺与设计协作

• 共享 DFMEA / DFM 报告
• 工厂提出可行改进方案
• 通过样品或小批量验证改进效果

Tip: 建立透明、双向沟通机制，避免信息孤岛和误解。

4. 供应链持续优化

长期合作不仅是采购合同，还包括 供应链能力优化：

1. 材料供应链优化
   • 与工厂、材料供应商共同确定稳定原料来源
   • 统一批次管理，减少批次差异
2. 模具维护计划
   • 定期保养、润滑、清洁
   • 模具寿命统计，预测更换周期
3. 生产能力升级
   • 高峰期协商排产计划
   • 关注设备更新或扩产能力
4. 质量数据分析
   • 建立 QC 数据库
   • 定期统计尺寸公差、返工率、客户投诉
   • 通过数据驱动改进

5. 总结 Part 5

长期合作策略的核心：

• 合同与知识产权保护：NDA + 模具归属 + 质量条款
• KPI 与绩效管理：量化供应商表现，建立奖惩机制
• 风险分担机制：模具、材料、紧急订单
• 沟通与项目管理：PM 制度、定期评审、透明反馈
• 供应链持续优化：材料管理、模具维护、生产能力升级、数据分析

Tip: 长期合作 = 价格+质量+速度+信任，短期低价无法替代长期稳定的供应链优势。