Design Capability Solution Provider

Our industrial designers are the bridge between the original product ideas and the engineers who develop the detailed design and prototypes. These teams are responsible for taking a concept and optimizing it for usability, appearance and manufacturing potential. These teams create value and provide solutions for both the user of the product and the manufacturing teams responsible for the mass production process through detailed designs, prototyping and technical support. We equip with common CAD/CAE software for product design and design analysis.

Concept from Customer Design

Wah Shing Toys offers design services for those customers who have a conceptual idea but have not yet come up with the right design. Our R&D team specializes in complete services of converting original ideas and concepts into products for mass manufacturing.

Modeling making

We have hands on well experience model makers and well-equipped in-house modeling shop, which can produce quick turnaround POC (proof of concept) models and TCM (tooling check model) by CNC or 3D printers. These prototypes can provide for our customers visual and play experience as actual final product.

Engineering department technical team commitment to customers

• Aims at best quality, shortest lead time, lowest cost
• Provides total project management and technical service
• Holds adaptive, innovative, professional and strive for excellence attitude

Project management capabilities

• Wah Shing Engineering provides a distinguishing WAE (Wah Shing Adaptive Engineering) service with upfront analysis report and feasible solutions to fit customers’ needs and depth.
• Our project managers (PM) have at least 15 years engineering hands on experience on toy and product development
• Well experienced to plan for the best fit development schedule, risk prevented and to closely monitor all project event details
• Customers can rely on the dedicated PM representing them as a simple contact window to fight for resources required for new product development (NPD) and launch on time, on cost and on quality with regular project progress report. We offer Agile project routing (customized) to reduce time to market.
• The Oracle Product Life-cycle Management (PLM) tool Agile is master controlling the project loading and resources allocation to best support all NPD.

Expert engineering teams capabilities

Wah Shing Toys is one of the leading toy OEM company with development and manufacturing experience and has stayed at trendy and high complexity and highly challenging toy product development position. Our engineering teams are casted by over 150 engineering experts from different engineering expertise age range from 30 to 55. Besides the well experienced engineering experts, the accumulated years of hands-on developing techniques and experience on product development are captured and systematically stored in the knowledge base in the Oracle Agile PLM system for new engineers training and future NPD references.

• Product engineers – Follow up product design debug, engineering sample making and design verifications, define engineering specifications and critical process control parameters.
• Mechanical and structural engineers – select and design proper mechanism and mechanical construction and material most suitable for the product application.
• Soft goods engineers – pattern marker design for outfits and soft toy, fabric material sourcing and selection, fabric part construction design and debug, hair rooting, grooming and special process evaluation.
• Electronics and control system engineers – circuit design, schematics review, PCB layout, component selection, control parameters and design margin verification, PCBA debug, design for testing. Familiar on 2.4G and Bluetooth communication application, using IR control, encoders, capacitive sensors, hall effect sensor, inductive proximity sensor, light sensor, MEMS (ultrasonics sensor, barometric, pressure sensors, gyroscopes, accelerometer), PID control, motor control, system power management on robotic product application.
• Chemical engineers – derive chemical formulation, sample making and verification, Toxicological Risk Assessment (TRA), chemical mixing process control for slime, fizz, mixing foam and special chemicals for product applications.
• Decoration and art design engineers – experience to follow up all kinds of decoration process such as spraying, tempo, silkscreen, heat transfer, ink jet printing, water transfer label, In-mold decoration, artwork development and mask making follow up.
• Packaging engineers – design product packaging construction, process selection, art film legal lines verifications and material selection
• Industrial and process engineers – design for automation, testing, line balance, process design and streamlining, manufacturing routing, process integration, value stream mapping, provide standard time for product costing.
• Tooling engineers – tool design, layout approval, provide cycle time standards, process integration, mold fabrication follow up.
• WES (Wah Shing Engineering Standards) includes EDS (Engineering Design Standards), EMS (Engineering Material Standards), EPS (Engineering Process Standards) and EOP (Engineering Operations Standards) holds a wide varieties of toy development and manufacturing knowledge ready for use by the worldwide toy makers.

Product Range capabilities

Our engineering teams with wide range product development experience covers hard toys, soft toys, fashion dolls, feature plush, electronic toys, robotic toys, chemical product, gifts and premium items as well as recent years extended capabilities on health product, infant caring product and personal protective equipment (PPE)

Toy product experience by categories

• Hard toys, playsets, construction toys
• Actions figures and fashion dolls
• Soft toys and feature plush
• Electronics, electro-mechanical toy and robotic gadgets
• Infant and Ride on products

NON toy product experience

• Personal protective equipment PPE, medical mask
• Breast pump health product, activity checkers
• Surveillance animal deterrent, Farm chemical Dispenser
• Beer dispenser

Process breakthroughs

• High precision fabric blocking application
• High precision fabric sewing and perfect seam matching
• Fabric insert molding
• 3D embroidery
• High precision dot matrix tempo printing for doll eyes
• DIJ printing for figurine facial decoration
• Multi-color multi material injection molding
• Injection with Gas ejection to replace roto casting
• Thick wall crystal eyes and thin wall injection molding

Mold making capabilities

We manage over 3,000 molds-per-year with in house mold making and subcontracting mold quality management under a Tooling Quality Management team (TQM) for wide variety of molds, such as simplest casting, precise polished super gross curved surface finishing, highly complex multi-slides molds, gas assist ejection, and fully automatic hot running molds for large volume, connected machine robots for multi color and multi material injection mold, crystal eye molds, fabric insert and high precision valves.

Intellectual property (IP) control capabilities

We strictly follow IP control discipline demanded by customers for all IP sensitive information throughout the entire product development process and sample making. Unique traceable code will be laser marked on each IP controlled part. Adopts sample dispatch track and trace coding system. Dedicated IP control sample room with anti-spy windows, 24X7 surveillance CCTV and security lock are standard set up.

ERP System (Oracle E-Business Suite)

Our ERP system is a fully integrated, comprehensive suite of business applications which integrates our major business processes and provides real time and consistent data for our management team.

MRP Process

Material Requirements Planning (MRP) is a part of our Oracle ERP System, Oracle module is ASCP (Oracle Advanced Supply Chain Planning) based production planning and inventory control system used to manage manufacturing processes. The system ensures materials and products are available for production and delivery to customers. The system also helps us to maintain the appropriate levels of inventory and plan manufacturing activities, delivery schedules and purchasing activities.

Product Lifecycle Management (PLM) System (Oracle – Agile PLM system)

Our PLM System allows us to manage product development information more efficiently through:

• Standardization of design and material spectification.
• Build knowledge base with historical data
• Efficient Schedule Monitoring of development cycle

Manufacturing Capabilities

Wah Shing Toys has an integrated production capability that guarantees one-stop, fast, high volume, high quality, and low-cost manufacturing solutions. Key processes are listed below.

Plastics Process

• Injection molding machine - over 500 machines ranging from 80 to 650 tons capacity
• Roto-casting oven
• Blow molding Machine

Additional in-house capabilities:

• Mold shop
• Color pigment mixing

Decoration Process

• Hand Spraying and Auto spraying machine
• Tampo printing
• Silk-screen printing

Electronics Assembly

Surface Mount Technology

• High speed surface mounting machines (Capacity: 6.1 millions pieces of chip components/day (For 13 sets SMT machines))
• Accuracy: Range for 0402 chip to 45 mm
• Automatic optical inspection (AOI) machine
• BGA IC mounters
• BGA x-ray inspection and re-work capabilities
• High-tech facilities such as BGA and 0201 chip placement machines

Bonding

• High speed machines (Capacity: 13.7 millions Aluminum wires/day (For 33 sets bonding machines))
• Accuracy: Lead pitch distance : 8 mils
• Fully Automated Bonding

Insertion

• Advanced forming and spraying wave soldering process

Printed Circuit Board (PCB) Assembly

• Soundproof cabinets for testing sensitivity of mixed pieces cells.
• 100% RoHs and non-phthalate production operation
• Shielded cabinet for Electric Magnetic Interference (EMI) shielding
• Conductive ground floor in SMT and bonding workshop for antistatic purpose

Soft Toy Operation

• Press and Laser Die-cut
• Machine Embroidery
• Sewing Machine with various aids and application
• Traditional hair rooting machine and Automatic rooting machine.
• High-tech facilities include laser die-cut machine, 20 heads embroidery machine, an auto-thread trimming machine and programmable sewing machine (movable work table)

General Assembly and Packing

• Dust-free assembly workshop
• Air-conditioned assembly workshop
• Reliable control system, programmable, high power, real time monitoring Ultra sonic welding machine and large scale production (over 200 assembly lines in 50 feet to 80 feet)
• Our high-tech facilities include x-ray machine and BGA x-ray machine for visual inspection

A. Quality Assurance (QA) Laboratories

The company has adopted ISO/IEC 17025 since 1994 and each of our plant has a testing lab since 1994. Our Chemical laboratory accredited by CNAS since 2008 and most of the physical laboratories accredited by our customers.

In general, we offer 4 kinds of labs :

• Physical and mechanical Laboratory - general toys and appliance product physical testing
• Chemical Laboratory - We are equipped with RoHS Analyzer - XRF, HPLC, GCMS, ICP and ICP-MS for the most updated toy regulation chemical testing such as heavy metal, Phthalate, BPA, RoHS, Chromium 6+ and formaldehyde testing
• Metrology Laboratory - high accuracy measurement equipments for dimension, colour, spring force measurement for in-house equipment calibration and dimension control. It also equipped with special testing equipment such as electrostatic test equipment, Laser Energy tester and Moisture Analyzer, Spectrophotometer for the ElectroStatic Discharge (ESD) and LED laser energy test.
• Face mask and microbiological laboratory - capable of testing the differential pressure, resistance to penetration by synthetic blood, bacterial filtration efficiency (BFE), particulate filtration efficiency (PFE) and microbial cleanliness for medical/non-medical face masks, as well as the microbial cleanliness (USP <61> and <62>) and preservative effectiveness (USP <51>) for toys.

B. Quality Assurance (QA)

The company has an individual QA team for each plants and these teams focus on design review, product specification setting up which cover all the safety, functional and reliability matters to meet the customer’s standard.

C. Quality Control (QC)

As part of quality department, Quality Control team aids for the Incoming Material quality control, In-process quality control with help from the Standard Quality Plan and systematic quality control tools.

D. Quality System (QS)

Quality System team is an individual section of quality department and directly reports to the head of Quality to align the quality system in between each business units. QS team holds the responsibility for the group base regulation requirement update according to constantly review on the international standards and customer requirements. Ahead for the regulations and prepare before the regulation/customer requirement update. QS team is helping the company to be one of the industrial leaders.