Powerful Processes

With so many startups and changeovers in short run, there is no margin for error. That’s why, at Donnelly, we’ve been defining and continuously refining a variety of precise high-level, Lean manufacturing processes since 1984. Leveraging a best-in-class ERP system, we make sure your projects are completed on-time and on-budget.

Here are some of the ways we handle complexities, including 12,000+ mold changeovers per year.

Every project is different. Different customer designs. Different molds. Different materials. Different processing. So how do we ensure repeatability and reliability every time?

Our proprietary Manufacturing Launch Process and Launch Team have the bandwidth and horsepower to launch an average of 150 molds a year.

Collaborating with your team, our manufacturing launch engineers, process engineers and project engineers ensure that your part is produced to spec, on time and on budget.

Need to transfer tools from a different molder? Or bring tools back to the U.S. from an overseas supplier for tighter controls, improved logistics, elevated customer support and shorter lead times?

Donnelly’s engineers employ practical solutions which focus on the overarching objective (to produce better parts), not simply the problem (to get the mold up and running).

Our proven process covers inspection, cleaning, repair, testing and process optimization for each mold – all the key elements of a successful transfer that can’t be left to chance.

Waste and inefficiency are impediments to service and success. Here’s where we meet, measure and attack waste every day.

A cross-functional team huddles in the War Room to review the last 24 hours of activity and to look for opportunities to improve results in the next 24 hours.

Customer orders are forecasted 14 days in advance of a deadline. Any roadblocks to delivering good products on time are identified. Action items are assigned and corrective actions are set in motion.

The result: Less wasted machine time, labor and materials. Problems are solved and people are allowed to focus on meeting our mission and take pride in their work. Customers are well served and their business needs are met.

Meeting or exceeding ISO standards since 1996, Donnelly’s aggressive Management Review of the Quality Management System is recognized as a best practice in the industry by third-party and ISO auditors.

Fierce commitment to quality measures, continuous improvement and customer satisfaction are recognized by certification to the ISO 9001:2015 standard.

Our quality management system supported and confirmed, thereby remaining suitable and effective in meeting the vital needs of our customers.

Why Donnelly

At Donnelly, we’ve built our business around your specific plastic injection molding needs.


Today, our 240 employees continue to focus and thrive on short run.

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When it comes to meeting crucial deadlines in short-run manufacturing, agility is paramount.

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Learn more about how we can help you achieve your critical short run objectives today.