How Dynacast Orchestrated a Complex Tooling Move

The Challenge: Plant Closure Opens a Complex Mission

When a long-established plant shut down, a leading player in the security products industry was faced with an urgent and complicated transition. The facility's ageing infrastructure, high labour costs, and inefficient tooling utilisation had made in-house production unsustainable. With most of the tooling contributing minimally to overall production spend, the decision was made to relocate dozens of tools—an ambitious move requiring speed, coordination, and technical precision.

But the road ahead wasn't simple. Rising cost pressures, logistical strain from shipping dozens of tools monthly, and unclear tooling documentation posed real threats to success. On top of that, inconsistent sampling protocols and missing information for secondary operations risked slowing everything down.

The Solution: A Smart Shift to Efficiency and Control

Dynacast's focus was not just on moving die cast tools—it was on optimising them for better performance and building a foundation for long-term value.

Dynacast brought deep expertise in precision casting, using an engineering-first approach to ensure every part was thoughtfully designed and accurately cast for optimal performance. This technical rigor was matched by speed without compromise—the team acted swiftly to meet tight timelines without ever cutting corners, maintaining the highest quality standards throughout. What truly set the project apart, however, was the partnership dynamic.

The Implementation: Prioritizing Medium-to-Low Volume Parts

Thanks to compatibility with the customer's existing equipment platforms, the Dynacast team was able to integrate the transferred tools with minimal disruption—often getting the die cast machines running within a day or two. Dynacast focused efforts where it mattered most: medium-to-low volume parts that offered the greatest strategic value, while also keeping future high-volume opportunities in view.

Capabilities That Count

The equipment used at Dynacast represented a major upgrade from the ageing machines of previous suppliers. Our ability to build both tools and machines in-house gave the team unique control over quality and lead times. And when added flexibility was needed, our collaboration with global teams—including engineering support from Asia—ensured nothing slowed progress.

The Results: Partnership, Performance, and Future Potential

Weekly check-ins, pilot runs, and a commitment to shared success laid the groundwork for a lasting strategic relationship. By avoiding supply chain disruptions during a critical transition, Dynacast not only ensured continuity but also improved tooling performance—extending tool life and setting the stage for future growth and opportunities.