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        • MaxxMacro®
          • Pallets
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          • Extensions, Vertical and Horizontal
          • Adapters, Angled, 90 Degree Etc.
          • Precision Vises
          • Wire EDM
          • Spare Parts and Accessories
          MaxxMacro WEDM Kit, Leveling adapter + Rail + SuperVise

          MaxxMacro WEDM Kit, Le...

          Regular price $5,895.00 USD
          MaxxMacro 54 User Kit Manual Chuck 62841S

          MaxxMacro 54 User Kit ...

          $2,550.00 USD
          MaxxMacro 70 Pneumatic Low Profile Chuck Rust Proof WEDM

          MaxxMacro 70 Pneumatic...

          Regular price $2,250.00 USD
          MaxxMacro (System 3R) 54 Manual QuickChuck Rust Proof WEDM 1

          MaxxMacro 54 Manual Qu...

          Regular price $695.00 USD
        • Wire-EDM
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          • A535/AQ535
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          • Makino
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          • U3 or U3 HEAT
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          • GFAC / Charmilles
          • Cut 1000 size
          • Cut 2000 - Agiecut Size 2
          • Cut 3000 - Agiecut Size 3
          • Cut E 600
          • Cut 300 & Cut P 550
          • Cut P 350 & Cut E 350
          • Cut 400 & Cut P 800
          • Cut 400 - Charmilles 640
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        • Maxx-ER®
          • Pallets 148, 115, 72, G, 100 and P
          • Spigots and Drawbars
          • Chucks
          • ER Collet Chucks
          • Holders
          • Masters and Gauges
          • Probes and Probe Tips
          • Extensions, Vertical and Horizontal
          • Adapters, Angled, 90 degree, etc.
          • 50 ,100, G Reference Plates
          • Wire EDM
          • Compact and Spare Parts
          Maxx-ER (Erowa) 154100 50 Stainless 100P Manual QuickChuck Chuck With Mounting Plate 125x125mm 2

          Maxx-ER 154100 100 P S...

          Regular price $1,150.00 USD
          Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER20C 1

          Maxx-ER 093999 50 Stai...

          Regular price $625.00 USD
          Maxx-ER (Erowa) 50 Aluminum Slotted Electrode Holder U25 2

          Maxx-ER 50 Aluminum Sl...

          Regular price $25.00 USD
          Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER32C 1

          Maxx-ER 093999 50 Stai...

          Regular price $625.00 USD
        • MaxxUPC®
        • MaxxVise®
        • Dovetail Holders
        • User Kits
        • Tombstones

        Maxx Tooling

        • MaxxMacro®
          Pallets
          Drawbars
          Chucks
          ER Collet Chucks
          Holders
          Master and Gauges
          Probes and Probe Tips
          Extensions, Vertical and Horizontal
          Adapters, Angled, 90 Degree Etc.
          Precision Vises
          Wire EDM
          Spare Parts and Accessories
          MaxxMacro WEDM Kit, Leveling adapter + Rail + SuperVise

          MaxxMacro WEDM Kit, Le...

          Regular price $5,895.00 USD
          MaxxMacro 54 User Kit Manual Chuck 62841S

          MaxxMacro 54 User Kit ...

          $2,550.00 USD
          MaxxMacro 70 Pneumatic Low Profile Chuck Rust Proof WEDM

          MaxxMacro 70 Pneumatic...

          Regular price $2,250.00 USD
          MaxxMacro (System 3R) 54 Manual QuickChuck Rust Proof WEDM 1

          MaxxMacro 54 Manual Qu...

          Regular price $695.00 USD
        • Wire-EDM
          RULERS AND DOVETAILS
          ACCESSORIES AND VISES
          WEDM CHUCKS
          Sodick
          • AQ750L (2001 on)
          • AQ900L
          • AQ1200L (Vertical)
          • AQ600
          • VZ300L
          • AG 400/AQ 400L
          • SL600G/ AG600L
          • A535/AQ535
          • More...
          Makino
          • U32J
          • U53J
          • U3 or U3 HEAT
          • EU43/SP43
          • Duo 43
          • SP64
          • U6
          • U86
          • More...
          GFAC / Charmilles
          • Cut 1000 size
          • Cut 2000 - Agiecut Size 2
          • Cut 3000 - Agiecut Size 3
          • Cut E 600
          • Cut 300 & Cut P 550
          • Cut P 350 & Cut E 350
          • Cut 400 & Cut P 800
          • Cut 400 - Charmilles 640
          • ‎More...
          Fanuc
          • 1iD/1iE
          • Alpha 1A
          • Robocut 1iA
          • Robocut 1iB
          • C400iA
          • More...
          Mitsubishi
          • FX1/FX10/FA10/FA10S
          • MD Pro 2/BA 8
          • MV 1200R
          • MV 2400
          • PA 10 Advance
          • ‎More...
          ONA
          • AF25
          • AF35
          • AV35
          • AF60
          • AV60
          • AD35
          • More...
          Seibu
          • M35B
          • M50B
          • M75B
          • More...
          Chmer
          • 432S
          • 643S
          • 743
          • More...
          Accutex
          • 300I
          • 500I
          • AU 600
          • More...
          Excetek
          • ‎
        • MaxxMagnum®
        • MaxxUPC®
        • Maxx-ER®
          Pallets 148, 115, 72, G, 100 and P
          Spigots and Drawbars
          Chucks
          ER Collet Chucks
          Holders
          Masters and Gauges
          Probes and Probe Tips
          Extensions, Vertical and Horizontal
          Adapters, Angled, 90 degree, etc.
          50 ,100, G Reference Plates
          Wire EDM
          Compact and Spare Parts
          Maxx-ER (Erowa) 154100 50 Stainless 100P Manual QuickChuck Chuck With Mounting Plate 125x125mm 2

          Maxx-ER 154100 100 P S...

          Regular price $1,150.00 USD
          Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER20C 1

          Maxx-ER 093999 50 Stai...

          Regular price $625.00 USD
          Maxx-ER (Erowa) 50 Aluminum Slotted Electrode Holder U25 2

          Maxx-ER 50 Aluminum Sl...

          Regular price $25.00 USD
          Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER32C 1

          Maxx-ER 093999 50 Stai...

          Regular price $625.00 USD
        • MaxxVise®
        • Dovetail Holders
        • SKU Compatibility
        • Media
      • MaxxMacro®
        • Pallets
        • Drawbars
        • Chucks
        • ER Collet Chucks
        • Holders
        • Master and Gauges
        • Probes and Probe Tips
        • Extensions, Vertical and Horizontal
        • Adapters, Angled, 90 Degree Etc.
        • Precision Vises
        • Wire EDM
        • Spare Parts and Accessories
        MaxxMacro WEDM Kit, Leveling adapter + Rail + SuperVise

        MaxxMacro WEDM Kit, Le...

        Regular price $5,895.00 USD
        MaxxMacro 54 User Kit Manual Chuck 62841S

        MaxxMacro 54 User Kit ...

        $2,550.00 USD
        MaxxMacro 70 Pneumatic Low Profile Chuck Rust Proof WEDM

        MaxxMacro 70 Pneumatic...

        Regular price $2,250.00 USD
        MaxxMacro (System 3R) 54 Manual QuickChuck Rust Proof WEDM 1

        MaxxMacro 54 Manual Qu...

        Regular price $695.00 USD
      • Wire-EDM
        • RULERS AND DOVETAILS
        • ACCESSORIES AND VISES
        • WEDM CHUCKS
        • Sodick
        • AQ750L (2001 on)
        • AQ900L
        • AQ1200L (Vertical)
        • AQ600
        • VZ300L
        • AG 400/AQ 400L
        • SL600G/ AG600L
        • A535/AQ535
        • More...
        • Makino
        • U32J
        • U53J
        • U3 or U3 HEAT
        • EU43/SP43
        • Duo 43
        • SP64
        • U6
        • U86
        • More...
        • GFAC / Charmilles
        • Cut 1000 size
        • Cut 2000 - Agiecut Size 2
        • Cut 3000 - Agiecut Size 3
        • Cut E 600
        • Cut 300 & Cut P 550
        • Cut P 350 & Cut E 350
        • Cut 400 & Cut P 800
        • Cut 400 - Charmilles 640
        • ‎More...
        • Fanuc
        • 1iD/1iE
        • Alpha 1A
        • Robocut 1iA
        • Robocut 1iB
        • C400iA
        • More...
        • Mitsubishi
        • FX1/FX10/FA10/FA10S
        • MD Pro 2/BA 8
        • MV 1200R
        • MV 2400
        • PA 10 Advance
        • ‎More...
        • ONA
        • AF25
        • AF35
        • AV35
        • AF60
        • AV60
        • AD35
        • More...
        • Seibu
        • M35B
        • M50B
        • M75B
        • More...
        • Chmer
        • 432S
        • 643S
        • 743
        • More...
        • Accutex
        • 300I
        • 500I
        • AU 600
        • More...
        • Excetek
        • ‎
      • MaxxMagnum® expand
        • Tombstones
        • Chucks
        • Reference Elements
        • Vises & WEDM
        • Spare Parts
      • Maxx-ER®
        • Pallets 148, 115, 72, G, 100 and P
        • Spigots and Drawbars
        • Chucks
        • ER Collet Chucks
        • Holders
        • Masters and Gauges
        • Probes and Probe Tips
        • Extensions, Vertical and Horizontal
        • Adapters, Angled, 90 degree, etc.
        • 50 ,100, G Reference Plates
        • Wire EDM
        • Compact and Spare Parts
        Maxx-ER (Erowa) 154100 50 Stainless 100P Manual QuickChuck Chuck With Mounting Plate 125x125mm 2

        Maxx-ER 154100 100 P S...

        Regular price $1,150.00 USD
        Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER20C 1

        Maxx-ER 093999 50 Stai...

        Regular price $625.00 USD
        Maxx-ER (Erowa) 50 Aluminum Slotted Electrode Holder U25 2

        Maxx-ER 50 Aluminum Sl...

        Regular price $25.00 USD
        Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER32C 1

        Maxx-ER 093999 50 Stai...

        Regular price $625.00 USD
      • MaxxUPC®
      • MaxxVise®
      • Dovetail Holders
      • User Kits
      • Tombstones

      Maxx Tooling

      • MaxxMacro®
        Pallets
        Drawbars
        Chucks
        ER Collet Chucks
        Holders
        Master and Gauges
        Probes and Probe Tips
        Extensions, Vertical and Horizontal
        Adapters, Angled, 90 Degree Etc.
        Precision Vises
        Wire EDM
        Spare Parts and Accessories
        MaxxMacro WEDM Kit, Leveling adapter + Rail + SuperVise

        MaxxMacro WEDM Kit, Le...

        Regular price $5,895.00 USD
        MaxxMacro 54 User Kit Manual Chuck 62841S

        MaxxMacro 54 User Kit ...

        $2,550.00 USD
        MaxxMacro 70 Pneumatic Low Profile Chuck Rust Proof WEDM

        MaxxMacro 70 Pneumatic...

        Regular price $2,250.00 USD
        MaxxMacro (System 3R) 54 Manual QuickChuck Rust Proof WEDM 1

        MaxxMacro 54 Manual Qu...

        Regular price $695.00 USD
      • Wire-EDM
        RULERS AND DOVETAILS
        ACCESSORIES AND VISES
        WEDM CHUCKS
        Sodick
        • AQ750L (2001 on)
        • AQ900L
        • AQ1200L (Vertical)
        • AQ600
        • VZ300L
        • AG 400/AQ 400L
        • SL600G/ AG600L
        • A535/AQ535
        • More...
        Makino
        • U32J
        • U53J
        • U3 or U3 HEAT
        • EU43/SP43
        • Duo 43
        • SP64
        • U6
        • U86
        • More...
        GFAC / Charmilles
        • Cut 1000 size
        • Cut 2000 - Agiecut Size 2
        • Cut 3000 - Agiecut Size 3
        • Cut E 600
        • Cut 300 & Cut P 550
        • Cut P 350 & Cut E 350
        • Cut 400 & Cut P 800
        • Cut 400 - Charmilles 640
        • ‎More...
        Fanuc
        • 1iD/1iE
        • Alpha 1A
        • Robocut 1iA
        • Robocut 1iB
        • C400iA
        • More...
        Mitsubishi
        • FX1/FX10/FA10/FA10S
        • MD Pro 2/BA 8
        • MV 1200R
        • MV 2400
        • PA 10 Advance
        • ‎More...
        ONA
        • AF25
        • AF35
        • AV35
        • AF60
        • AV60
        • AD35
        • More...
        Seibu
        • M35B
        • M50B
        • M75B
        • More...
        Chmer
        • 432S
        • 643S
        • 743
        • More...
        Accutex
        • 300I
        • 500I
        • AU 600
        • More...
        Excetek
        • ‎
      • MaxxMagnum®
      • MaxxUPC®
      • Maxx-ER®
        Pallets 148, 115, 72, G, 100 and P
        Spigots and Drawbars
        Chucks
        ER Collet Chucks
        Holders
        Masters and Gauges
        Probes and Probe Tips
        Extensions, Vertical and Horizontal
        Adapters, Angled, 90 degree, etc.
        50 ,100, G Reference Plates
        Wire EDM
        Compact and Spare Parts
        Maxx-ER (Erowa) 154100 50 Stainless 100P Manual QuickChuck Chuck With Mounting Plate 125x125mm 2

        Maxx-ER 154100 100 P S...

        Regular price $1,150.00 USD
        Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER20C 1

        Maxx-ER 093999 50 Stai...

        Regular price $625.00 USD
        Maxx-ER (Erowa) 50 Aluminum Slotted Electrode Holder U25 2

        Maxx-ER 50 Aluminum Sl...

        Regular price $25.00 USD
        Maxx-ER (Erowa) 50 Stainless ER Collet Chuck ER32C 1

        Maxx-ER 093999 50 Stai...

        Regular price $625.00 USD
      • MaxxVise®
      • Dovetail Holders
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      22/ Aug, 16 0 comments

      Here's a rule for you to remember... If you don't do a DOE then you did not qualify the process.

      Want 40% Faster Cycle Times with 90% Less Scrap?

      What many miss in manufacturing isn’t just mold validation; it’s process validation. Most follow tooling validation, which gives you a mold capable of producing acceptable parts. But it doesn’t guarantee a process that consistently produces those parts within required limits.

      After 20+ years in the industry and thousands of tryouts, I’ve seen mold validation used to qualify the process only twice. In FDA-regulated environments, validation is a requirement, but in automotive and consumer goods, it’s rare. Why?

      How to Tell if Your Process is Truly Validated

      Did you use these tools?

      Process validation is a structured approach with three key stages: Process Design, Process Qualification, and Continued Process Verification. Here’s a breakdown:

      1. Design of Experiment (DOE)

      DOE identifies relationships and sources of variation quickly. It’s essential to determine if this step is worth it through a cost-benefit analysis. If you skip DOE, you haven’t fully validated the process.

      2. Quality by Design (QbD)

      QbD ensures quality is built into products from the beginning, not just tested at the end. Especially crucial for critical molding processes, it allows early-stage design adjustments to address potential risks and quality issues before they arise.

      3. Process Analytical Technology (PAT)

      PAT measures critical process parameters (CPP) and critical quality attributes (CQA) in real-time, allowing for timely feedback and adjustments. It’s used both in design and production to ensure a process stays within qualification standards.

      4. Critical Process Parameters (CPP)

      These are the operating parameters essential to keeping the product within quality guidelines. Monitoring CPP ensures output remains consistent.

      5. Critical Quality Attributes (CQA)

      CQAs are the attributes necessary for defining product quality, and monitoring these ensures that the final product meets all required standards.

      6. Design Space Verification

      This step confirms that quality can be maintained within a defined range of input and operating variables, providing a safeguard against variability.

      7. Process Qualification

      At this stage, the process design is evaluated to ensure it meets production goals. Equipment and production processes are proven to deliver quality outputs, setting the foundation for consistent manufacturing.

      8. Continued Process Verification

      Ongoing monitoring throughout production to ensure everything remains within control. Deviations are flagged and adjusted to maintain consistency.


      Benefits of Following This Process

      • 40% Faster Cycle Times
      • 90% Less Scrap — triple savings on materials, time, and costs
      • Double the Unattended Production Hours
      • Higher PPE Turnover

      What’s the Cost of Implementing This?

      If you’re not already following these steps, you're likely paying for it threefold in inefficiencies and quality issues. Investing in a comprehensive process validation can save you time, materials, and resources—delivering a process that produces acceptable parts within limits, every time.

      Tags: edm tooling, Informative, injection molding, Maxx-ER, MaxxMacro, tool and mold
      Share Share on Facebook Pin it Pin on Pinterest Tweet Tweet on Twitter

      Maxx Tooling

      EIN 98-1674380HST/GST 793130078RC0001

      USA

      41000 Woodward Ave, Bloomfield Hills, Mich, 48304

      Canada

      4145 North Service Road Burlington L7L 4X6

      Canada

      2545 North Talbot Rd Unit 16 Tecumseh, Ontario N0R1L0

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      Maxx Tooling® MaxxMacro® MaxxMagnum® Maxx-ER® MaxxUPC® MaxxVise® are all registered trademarks of 2726373 Ontario Inc. "Maxx Tooling" Unlicensed use is prohibited. System 3R®, Macro®, EROWA® and FCS® company names are trademarks™ or registered® trademarks of their respective holders. Use of them does not imply any affiliation with or endorsement by them.

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