Step Eleven: Works Like & Looks Like Models – Once these works like and looks like models are ready from the factory they are sent to the account team for review by both the client and the licensor if necessary. This will be the final approval stage prior to beginning to tool for the project and any and all changes need to happen at this stage. Once these have been reviewed and approved by all parties they are returned to Hong Kong so that the factory can begin to start tooling.


Step Twelve: View Drawings & Process Controls – For most projects, you should request from the factory that they provide Exploded View Drawings and Process Control Charts. What these two documents are for is to show that the factory has understood exactly what it is they are producing for you. With the exploded view drawings, they are showing an engineering drawing that details how each piece will be made an assembled. With the process control chart, this is a guideline to demonstrate all of the steps that will be used in the manufacturing of the product. By having your engineers and quality assurance staff review these documents you can determine that the factory understands exactly what you have asked them to produce and that it can be done.

Step Thirteen: Inserts, Decals & Polybags – At this stage you will need to receive from the creative department all of the copy and artwork that is required for the production of the inserts, decals or polybags used on this project. This is usually provided in the form of film or a disk. These will be sent to your Hong Kong office who will review them and pass them along to the factories. The factories will then provide proof sheets on each item for review and approval by the client and licensor if necessary prior to going into production.

Step Fourteen: Tooling First Shots – The tooling is now complete and we will begin to see “First shots” (also known as “Test Shots”) out of the mold. These are the first parts that are injected from the tool and we evaluate them for size and function. These have not been decorated yet and are not typically shared with the client. It allows your engineers to see the parts and make any adjustments if necessary to the tool prior to going into production.

Step Fifteen: Limit Set Samples and Meeting – After the first shots have been reviewed and any modifications have been made to the tool, a request is made to the factory to provide pre-production samples. These samples will be representative of the production line product and will be used for a “limit set” meeting with the client. At the limit set meeting these samples will be reviewed for decoration, function and safety to determine they are ready to proceed in to production. Any changes or defects that occur at this stage have to be taken care of prior to going in to production.