Link resin lot, mould, shot and paint line to every bumper and trim part shipped.

A bumper fascia begins as dried polypropylene pellets with talc, melts in a press barrel, packs into a steel mould through a hot runner and cools. Painting, flame treatment, vibration welding, heat staking of clips and a check on the gauging fixture follow before the rack is wrapped. Every step can add its own defect.

Settings and lot stay with every part. If a door trim warps or a snap-fit tab cracks, the mould, the press, the resin lot and the paint batch sit one click apart. Without that link, a quality engineer opens press logs, booth sheets and rack lists one by one, hoping the dates agree before the eight-discipline corrective action report is due.

Orders arrive as weekly releases and often as a sequenced call-off. Parts must reach the vehicle line in build order, so racks are packed back to front and counted twice at the dock. Planners match presses to moulds by clamp tonnage, load resin and masterbatch, and plan colour changes around purge time and the regrind ratio. Dew point on the desiccant dryer is checked before a lot is charged into a hopper. Colour changes eat press time.

Operators log cycle time, shot weight and rejects for flash, sink marks, short shots and silver streaks. Moulds carry a shot count and go to the tool room for cleaning, vent polishing or ejector pin repair on schedule. A mould back from the tool room runs a trial shot first, and the first good parts are kept as the reference sample for the shift. Painted parts move to the booth, then to assembly benches for clips, grommets and foam seals. Gauges and checking fixtures decide what ships. Nothing leaves unmeasured.