I worry about hidden delays. I feel pressure when jobs slip. I built a clear lead-time playbook. It cuts risk. It gives firm dates I can defend.
Most customized undercarriage parts ship in 30–60 days, while OEM programs run 45–90 days. Lead time usually starts after final drawing approval and deposit. New molds often take 2–6 weeks and cost $2,000–$15,000+. A signed plan with milestones can guarantee schedule, subject to materials and holidays.
I will show you exact time drivers, simple ways to cut delay, and what “guaranteed schedule” really means. I will also share real cases I faced, so you can plan with confidence.
How much longer does a custom order take compared to a standard order?
I once thought “custom” meant chaos. I was wrong. I learned that time grows in simple steps. I now size the gap and lock dates up front.
Custom orders usually add 2–4 weeks beyond standard parts of the same type. Simple changes like logo marks or paint can add 7–10 days. Deeper changes like new heat treatment or a new interface can add 3–6 weeks, especially when validation is needed.
What adds time for custom work
I see three big drivers. First, engineering review and DFM 1 add days if specs are unclear. Second, tooling or fixture changes 2 add weeks if we must build or tune parts. Third, validation adds time when we need samples and tests before mass build. When I align these three with you early, the extra time stays small.
Typical ranges by part type
Below is a clear view I use in my planning. It compares a standard order and a similar custom order of common undercarriage parts. I keep the language simple, and I add a note for each line.
| Part type | Standard lead time | Custom add-on time | Typical total for custom | Notes |
|---|---|---|---|---|
| Track roller | 15–25 days | +10–20 days | 25–45 days | Heat treatment can push add-on time to 3 weeks. |
| Carrier roller | 15–25 days | +10–20 days | 25–45 days | Simple logo or paint adds ~7–10 days. |
| Idler | 20–30 days | +15–25 days | 35–55 days | Casting pattern or machining change adds time. |
| Sprocket | 20–30 days | +15–30 days | 35–60 days | Tooth profile and hardness drive time. |
| Track chain | 25–35 days | +15–30 days | 40–65 days | Bush hardness and press-fit checks add steps. |
| Track shoe (plate) | 20–30 days | +10–20 days | 30–50 days | Hole pattern or thickness change adds time. |
How I keep the gap small
I use a short list. I lock drawings and tolerances first. I confirm tool status 3 next. I check material stock on day one. I plan samples and tests with a set date and a clear pass rule. I also ask for the holiday map 4 and the line load picture. When I did this on a custom sprocket last year, I cut the extra time from 5 weeks to 3 weeks. I did it by approving a hardness window early and by using an existing fixture with a small shim.
I also watch season swings. Before Spring Festival, I add two weeks buffer. In one case, I moved a PO two weeks earlier. The line then started before the peak, and I saved 10 days. I also ask for a second shift 5 on short runs. It is not free, but it can close a gap in a rush job.
Does my lead time start from the approval of technical drawings?
I learned this the hard way. I once counted time from the PO date. I missed the drawing loop. I lost two weeks. I never do that now.
Lead time should start from final approval of technical drawings, BOM, and specs 6, plus receipt of the deposit. If samples are required, the mass production clock starts after sample approval unless the contract says otherwise.
What “start of lead time” means in my contracts
I write it in plain words. “Lead time starts when both sides sign off the final drawings and specs, and when the deposit arrives in our bank.” I also add, “If a first article (FAI) 7 or golden sample is required, mass production lead time starts after FAI approval.” This keeps the rule clear. It also avoids disputes when there is a design change mid-way.
The approval path that drives the clock
I follow a simple path:
- I freeze the drawing. I make sure every tolerance is clear. I add surface finish, heat treatment 8, coating, and hardness.
- I run a DFM check. I confirm machining steps, fixtures, and gauge plans.
- I confirm material grade and source. If it is a special alloy 9, I place the material PO early.
- I set inspection plans. I agree on the control plan and the sampling level.
- I sign the PPAP 10 or FAI list if it is an OEM project.
- I send the proforma invoice. You send the deposit.
- We both sign the milestone sheet.
Only then do I say the clock starts. If you change the drawing later, I pause the clock. I then add time for the new review. I keep this strict because I want to hit your dates. It also protects both sides if a new test or process appears.
A short story that taught me this rule
I had an idler with a tight runout spec. We rushed the PO. We forgot to lock the gauge. The first sample failed. We lost 8 days while we built a new gauge and re-measured. Now I never start the lead-time clock until we lock the gauge list and all specs.
What is the cost and lead time for creating a new mold?
I once tried to skip a new mold to save money. I spent more later on rework and time. I now ask for a clear tooling plan 2 on day one.
Most undercarriage molds and dies cost $2,000–$15,000+, and they take 2–6 weeks. Simple fixtures can be faster and cheaper. Complex forging dies and large casting patterns cost more and take longer.
Typical tooling for undercarriage parts
I deal with three tooling types most of the time. I see forging dies for sprockets and links. I see casting patterns and core boxes for idlers. I see machining fixtures and gauges for rollers and chains. I also see heat-treatment fixtures that hold parts in shape during quench. Each tool type has its own cost and time. The table below shows a clean view.
| Tooling type | Common use | Cost range (USD) | Lead time (calendar days) | Notes |
|---|---|---|---|---|
| Closed-die forging die | Sprockets, links | 5,000–20,000 | 20–40 | Extra time for die steel heat treatment. |
| Casting pattern + core boxes | Idlers, hubs | 3,000–12,000 | 15–30 | Add 7–10 days for sample castings. |
| Machining fixture + gauges | Rollers, hubs, pins | 1,500–6,000 | 10–20 | Often the fastest path to start. |
| Heat-treatment fixtures | Rollers, sprockets | 1,000–4,000 | 7–15 | Reduces distortion; lowers rework risk. |
What drives tooling time and cost
I watch three things. Part size and shape set die steel size and machining time. Tolerance and hardness drive gauge and fixture complexity 3. Surface and coating rules can need special inserts or protection. When a die has deep teeth or a thin web, I plan an extra test shot. I also include time for T0 and T1 trials. I want room to polish the die and correct shrink.
I lower the tool bill in two ways. First, I reuse base plates and fixture bodies we already have. Second, I agree with you on a staged tool 2. I start with a soft die for trials, then I cut a hard die for mass runs. This splits risk. In one sprocket project, we paid $3,500 for a soft die and made fast samples in 12 days. We fixed the tooth tip once. Then we made the hard die in 21 days. The total still beat a single hard die that might need two reworks.
Payment and ownership
I keep this simple. If you pay the tool fully, you own it. We stamp your tool number on it. We store it and insure it. If we amortize the tool 2 in part price, we own it until the amortization ends. We write this in the contract so there is no doubt later.
Can I get a guaranteed production schedule for my OEM orders?
I heard this many times. I want a “guaranteed” plan too. I learned that a plan can be firm if we lock inputs and set clear rules for changes.
Yes. You can get a guaranteed schedule with fixed milestones and penalties 10 for supplier delay. It requires locked drawings and specs, a deposit, confirmed material, and a signed change-control rule. Holidays and force majeure must be listed in the plan.
What I include in a guaranteed plan
I use a milestone sheet 10 that both sides sign. It shows dates for each stage. It shows who owns each step. It shows pass rules. It also lists what can pause the clock. Below is a sample plan I used for an OEM idler. The dates are in weeks from the start point.
| Stage | Owner | Duration (weeks) | Output |
|---|---|---|---|
| DFM + drawing freeze | Both | 1 | Signed drawings, control plan |
| Tooling design + kick-off | Supplier | 1 | Tool drawings, purchase order |
| Tooling build (T0) | Supplier | 2 | T0 parts |
| T0 review + die tune (T1) | Both | 1 | T1 approval or rework list |
| Material procurement | Supplier | 1 | Mill certs, inbound receipt |
| Pilot run + FAI/PPAP | Supplier | 1 | FAI report, PPAP Level 3 |
| Mass production | Supplier | 2–3 | 100% QC records |
| Pre-shipment inspection | Both/3rd | 0.5 | PSI report, pack list |
| Packing + export clearance | Supplier | 0.5 | Export docs, booking |
The rules that make the plan “guaranteed”
I add simple rules. The plan starts only after we freeze drawings and receive the deposit 6. I state that any change request 1 pauses the clock until both sides sign a new date. I add a clause for penalties if we miss our dates for reasons we own. I also add a bonus for early ship if you need it. I list all public holidays 4. I lock the freight forwarder 5 or at least the Incoterms. This keeps handovers clean.
How I track and report progress
I use a shared Gantt and a weekly call. I also give you a cloud folder with photos, inspection sheets, and tool shots. I show live line videos on key days like pilot run and FAI. I share a simple dashboard: green means on plan, yellow means risk, red means miss. When I spot yellow, I act in 24 hours. I pull forward material. I add shifts. I bring in a second machine 5 for bottlenecks. This saved me two weeks on a track chain order last year when the heat-treat oven went down for service. I moved the lot to our backup oven at night, and we kept the ship date.
What can still shift dates
I am honest here. Force majeure 4 can hit any plan. Port closures, sudden power cuts, or a COVID-like event can break dates. Also, a special alloy 9 with long mill time will add days if the mill slips. I lower this risk by dual-sourcing steel 9 when possible and by holding safety stock for repeat OEM parts. If you place a blanket order 6 for the quarter, I can place material POs early. This pulls risk out of the critical path.
Conclusion
I use clear start rules, simple milestones, and fast feedback. I plan tooling 2 early. I watch holidays 4 and material 9. I protect your date with buffers and backups.
Footnotes
1. Learn about Design for Manufacturing (DFM), crucial for initial spec alignment. ↩︎
2. Explore details on tooling and fixture amortization for custom parts production. ↩︎
3. Understand why confirming tool status and gauge complexity matters for schedule adherence. ↩︎
4. See global holiday maps and force majeure clauses affecting production timelines. ↩︎
5. Information on capacity planning, like adding a second shift or machine, to reduce delays. ↩︎
6. Guidance on what constitutes final drawings, BOM, specs, and blanket order terms. ↩︎
7. Definition and process for a First Article Inspection (FAI) in OEM manufacturing. ↩︎
8. Best practices and common parameters for heat treatment of wear parts. ↩︎
9. Sourcing considerations for special alloy dual-sourcing to mitigate material risks. ↩︎
10. Best practices for creating guaranteed schedules with milestones and PPAP requirements. ↩︎