Early Supplier Developemental Input

Early Supplier Early Supplier

DevelopmentalDevelopmental InputInputCortec Precision Sheetmetal and Machining

March 2012

Innovative Solutions for Commodity Specific Manufacturing

IntroductionIntroduction• How valuable is supplier input when it comes to minimizing design cost, cost How valuable is supplier input when it comes to minimizing design cost, cost

effective materials and cost efficient processing for your new product? effective materials and cost efficient processing for your new product?

• Early Supplier Developmental Input (ESDI) is a 2Early Supplier Developmental Input (ESDI) is a 2ndnd set of eyes at the front end of set of eyes at the front end of the NPI process that can lead to major producibility and procurement the NPI process that can lead to major producibility and procurement advantages.advantages.

• Cortec has an ESDI Program that will provide critical risk assessment as it Cortec has an ESDI Program that will provide critical risk assessment as it pertains to the manufacturing of your new product. DFX; DFP, DFM & DFT pertains to the manufacturing of your new product. DFX; DFP, DFM & DFT observations on everything from Raw Material, Outside Services, Procured observations on everything from Raw Material, Outside Services, Procured Components, Logistics, Packaging and Shipping. Components, Logistics, Packaging and Shipping.

• Real-time consultation on the Quality Output of materials when processed Real-time consultation on the Quality Output of materials when processed through our manufacturing facility.through our manufacturing facility.

• By providing input on materials that work best with a specific child prototype or By providing input on materials that work best with a specific child prototype or electromechanical parent design, those contributions prevent potential problems electromechanical parent design, those contributions prevent potential problems during manufacturing. By identifying these issues in advance, you're more likely during manufacturing. By identifying these issues in advance, you're more likely to experience a smooth product realization process once your new product has to experience a smooth product realization process once your new product has been launched.been launched.

Cortec Precision Sheetmetal 2011

Early Developmental SolutionsEarly Developmental Solutions

When you send Cortec an RFQ it will be reviewed by our Estimating Team (ET).When you send Cortec an RFQ it will be reviewed by our Estimating Team (ET).

Our E.T. has Sheet Metal & Frame Manufacturing, Machine Shop, Our E.T. has Sheet Metal & Frame Manufacturing, Machine Shop, Mechanical/Engineering, Add Value Assembly, NPI Development and Product Mechanical/Engineering, Add Value Assembly, NPI Development and Product Transfer experience.Transfer experience.

They possess knowledge of material pricing and services related to your Build To They possess knowledge of material pricing and services related to your Build To Print fabrication and assembly needs.Print fabrication and assembly needs.

Our Drawing Process includes DFX feedback during conceptual design stage.Our Drawing Process includes DFX feedback during conceptual design stage.

We are proficient at expediting and providing real-time solutions.We are proficient at expediting and providing real-time solutions.

Actively propose Integrated solutions.Actively propose Integrated solutions.

Advise on potential processing inefficiencies.Advise on potential processing inefficiencies.

Make logical progression of design recommendations from NPI thru production life Make logical progression of design recommendations from NPI thru production life cycle and value-added assembly.cycle and value-added assembly.

Our Experts provide cost impact analysis when revision changes.Our Experts provide cost impact analysis when revision changes.

PFMECA reporting can be conducted.PFMECA reporting can be conducted.

Ensure lines of communication are open and maintained daily to interface with Ensure lines of communication are open and maintained daily to interface with corresponding personnel.corresponding personnel.

Capable of working on special projects from NPI to Production transition.Capable of working on special projects from NPI to Production transition.


ESDI DFP ReportingESDI DFP Reporting


Microsoft Excel Worksheet

DFP - Material Assessment & Material Budgetary Quote

sample

TYPE

BOM Item

Number

Metric MaterialDescription and Imperial

Equivalent

QTY Required

to build 2 Frames

Metric 1, 2, & 3 200 x 100 x 10MM WALL RECT TUBE 4

Imperial "8" x 4" x .375 WALL A500B STEEL,

RECT TUBE 4

Metric 4 150 x 100 x 8MM WALL RECT TUBE 4

Imperial "6" X 4" X .312 WALL A500B STEEL,

RECT TUBE 4

Metric 5 & 7 100 x 50 x 8MM WALL RECT TUBE 5

Imperial "4" X 2" X .312 WALL A500B STEEL,

RECT TUBE 5

Metric 8 32MM THK, PL STRUCTURAL STEEL 1

Imperial "2" X 1-1/4" THK STEEL RECT FLAT

BAR 1

Metric 102.5MM (MILD CARBON HRS STEEL

PLATE, A36) 1

Imperial "12 GA CRS (0.1046) ASTM A1008 CS

TYPE B 1

Metric 6

19MM THK PL, STRUCTURAL STEELSUPPLIER DOES NOT SUPPORT,

NEXT SIZE UP IS 20MM (.7874 THK) 1

Imperial ".750 THK PLT ASTM A36

48" x 96" 1

Metric 913MM THK, PL STRUCTURAL STEEL

32" X 60" 1

Imperial "

HOT ROLLED PICKLED & OIL .500 (PLATE A36)

32" x 48" 1Metric 11 COPPER SH, 1MM THK 1

Imperial ".040 THK, (1/4 HARD) OFE COPPER

C10100 HO1, ASTM B 152 1

Using a sheet metal cover as an Using a sheet metal cover as an example, Is it possible that the example, Is it possible that the fasteners you are using could fasteners you are using could be substituted for a less be substituted for a less expensive product or be expensive product or be integrated in our factory at the integrated in our factory at the next level of assembly? next level of assembly?

Cost savings pass through to Cost savings pass through to you when suggesting alternative you when suggesting alternative materials or processing ideas materials or processing ideas that work as effectively but cost that work as effectively but cost much less because they are much less because they are incorporated into your design incorporated into your design from the very start. from the very start.

ESDI DFM ReportingESDI DFM Reporting


ESDI: 1. Instead of using CLS-832-1 Cortec suggested using SP-832-1.

Why? Pem product technology has advanced and supplier created a new type of hardware designed specifically for installment into Stainless Steel base material. This new Pem product eliminates the need to tack weld the old type of hardware customarily used resulting in cost savings. 15% per part cost savings include elimination of tack weld, grinding and additional regraining of exterior surfaces to remove weld discoloration in the manufacturing Sequence of Events (SOE).

• Quality of new product is directly related Quality of new product is directly related to how involved your ESDI partner is at to how involved your ESDI partner is at the beginning of the NPI process. When the beginning of the NPI process. When consulting Cortec during the development consulting Cortec during the development stage, expect to have a product designed stage, expect to have a product designed with the right materials that conform to with the right materials that conform to drawing specifications.drawing specifications.

• When products are designed When products are designed withoutwithout the the contribution of an ESDI partner, there's a contribution of an ESDI partner, there's a possibility requested materials will not possibility requested materials will not work well with the final product. Materials work well with the final product. Materials used in the production of your new used in the production of your new product could be inconsistent, laborious product could be inconsistent, laborious and very expensive to incorporate or and very expensive to incorporate or rework. rework.

• Cortecs’ ESDI solution is to provide an Cortecs’ ESDI solution is to provide an onsite resource and be an adjunct onsite resource and be an adjunct member of your Engineering team.member of your Engineering team.

ESDI: Quality Review ESDI: Quality Review


Flat Head Screws• Flat Head Screws

supposed to be removed.• Cause: Frame

manufacturer failed to remove Flat Head Screws before painting.

• Type of failure – Minor, weld department did not follow customer approved OMS.

• Action: Option to Return to supplier or PAINT frame.

Cortec Precision Sheetmetal Confidential

Slide - 1

Metal Filler Missing• Workmanship

• Failure to Follow OMS

• Type of failure – major

• Action: Rework by stripping paint from seam and repeat OMS #12 STEPS 1-15


Slide - 1

ESDI Solutions identified during RFQ ProcessESDI Solutions identified during RFQ Process

& change control& change control



Slide - 1

RFQ

• Estimators Review RFQ Package

• Prepare Pre-FMEA statement• Create Redline drawing to WI 7.1.3• Adds Comment to Quote Comment Field.

• Estimators send Quote Letter to Customer along with Pre-FMEA statement and Redline drawing file.• Adds Popup Note in History Tab and clicks Popup Notify Note

• Customer places order.• Customer Service sees Popup notification and triggers SPS Process.

• Customer places order.• Customer Service sees Popup notification and triggers SPS Process.

• ME confirms need for SPS and SPS details.

• ME always attaches revised redline to FabriTRAK.• Must attach to BOTH Quote and Router.

• ME confirms redline created by Estimator.

• ME Reviews drawing files for any other omissions that will prevent product realization during WIP.

• ME gathers data and updates the redline drawing file if required.

• ME files SPS / PR / (other customer acronym).• Adds comments to FabriTRAK quote comment field.

• ME updates router and adds comments to transaction log.

• ME updates router and adds comments to transaction log.

• ME notifies ALL departments affected by SPS submittal.• Estimators• Customer Service•FAI Team

• ME saves a copy of the solution in the Q:/Drive Part number folder.• Adds comments in Quote and Router, attaches solution to FabriTRAK.

RFQ Processing and Identification of ESDI Opportunities, DXF reporting and design challenges

Applying our ESDI approach affords the opportunity to reassure optimal Applying our ESDI approach affords the opportunity to reassure optimal “design implementation” for manufacturability and other processing risks in a “design implementation” for manufacturability and other processing risks in a timely manner, enabling Research and Development the opportunity to timely manner, enabling Research and Development the opportunity to respond with minimal impact to your product release schedule. respond with minimal impact to your product release schedule.

This fully-integrated and efficient approach assures that your company This fully-integrated and efficient approach assures that your company reduces costs because it allows earlier identification of processing issues, reduces costs because it allows earlier identification of processing issues, and it applies your set tolerance for risk in a consistent manner. and it applies your set tolerance for risk in a consistent manner.

Enables real-time responsiveness and effective direct design input.Enables real-time responsiveness and effective direct design input.

Allows significant processing alternatives to control risk, cut cost and improve Allows significant processing alternatives to control risk, cut cost and improve quality. quality.

Provides consistent risk analysis, assessment and reporting.Provides consistent risk analysis, assessment and reporting.

Conduct risk control validation .Conduct risk control validation .

Cortec guarantees a fully- integrated and value-added approach towards Cortec guarantees a fully- integrated and value-added approach towards assessing and improving your design implementation. assessing and improving your design implementation.

Early Developmental Input BenefitEarly Developmental Input Benefit


ESDI Benefit: Quantitative ResultsESDI Benefit: Quantitative Results


12ncDescription2010

Cosmetic Class A Finish,

2 sidesQ3 2011

Cosmetic time savingsClass A Finish Outside SurfaceClass C Finish Inside Surface Quantitative savings 12-02-2011 TQS

xxxx.000.88882 RS XTIV LO-FRONT PANEL IL LSY244.31$ 35.12$ Time savings 1 minute per part

1.08$ 34.04$

xxxx.000.88882 RS XT4 INN.COV. LSY2 RH ASSY289.78$ 272.33$

Multiple piece assembly, Time savings 5 min per side; 10 min.

total 10.83$ 261.50$

xxxx.000.88882 RS XT4 INN.COV. LSY2 ILL ASSY258.23$ 250.17$

Multiple piece assembly,Time savings 5 min per side; 10 min.

total 10.83$ 239.34$

xxxx.000.88882 RS XT4 INN.COV.LSY1/2 MID ASSY221.93$ 210.84$


total 10.83$ 200.01$

xxxx.000.88882 RS XT4 INN.COV. LSY1 RH ASSY283.17$ 271.86$


total 10.83$ 261.03$

xxxx.000.88882 RS XT4 INN.COV. LSY1 ILL ASSY294.37$ 279.65$


total 10.83$ 268.82$

xxxx.000.88882 RS AIR SHOWER COVER PLATE ASSY453.42$ 417.18$ Time savings 10 min. per side;

20 min. total 21.66$ 395.52$ xxxx.000.88882 RS XT4 TOP COVER ILL LSY2 ASSY551.00$ 526.21$ Time savings is 10 min. 10.83$ 515.38$ xxxx.000.88882 RS XT4 TOP COVER MID LSY2 ASSY553.91$ 526.23$ Time savings is 10 min. 10.83$ 515.40$ xxxx.000.88882 RS XT4 TOP COVER RH LSY2 ASSY596.50$ 570.84$ Time savings is 10 min. 10.83$ 560.01$ xxxx.000.88882 RS XT4 TOP COVER ILL LSY1 ASSY554.97$ 527.25$ Time savings is 10 min. 10.83$ 516.42$ xxxx.000.88882 RS XT4 TOP COVER MID LSY1 ASSY440.00$ 420.26$ Time savings is 10 min. 10.83$ 409.43$ xxxx.000.88882 RS XT4 TOP COVER RH LSY1 ASSY535.75$ 508.98$ Time savings is 10 min. 10.83$ 498.15$ xxxx.000.88882 RS XT4 FRONT COVER LSY1 ASSY421.96$ 400.86$ Time savings is 20 min. 21.66$ 379.20$ xxxx.000.88882 RS XT4 UP-FRT COVER IL-Y2 ASSY326.97$ 311.29$ Time savings is 7 min. 7.58$ 303.71$ xxxx.000.88882 RS XT4 FRONT COVER RH-Y2 ASSY424.90$ 390.04$ Time savings is 5 min. 5.42$ 384.62$ xxxx.000.88882 RS XT4 FRONT COVER MID-Y2 ASSY446.11$ 384.73$ Time savings is 5 min. 5.42$ 379.31$ xxxx.000.88882 RS LOS RH COVER ASSY580.46$ 554.52$ Time savings is 20 min. 21.66$ 532.86$ xxxx.000.88882 RS XT4 COVER MOUNT STRIP SA-A71.37$ 62.10$ Machined flat barxxxx.000.88882 RS XT4 COVER MOUNT STRIP SA-B69.07$ 60.39$ Machined flat bar

7,418.18$ 6,980.85$ Total 6,654.75$ Percentage Quantitative Savings -24.67%

Early Developmental Input

New Product DesignIssues & Issues &

OpportunitiesOpportunities

IdentifiedIdentified

Material Processing Issue

Mechanical Fit Issue

Early Supplier Early Supplier

Developmental InputDevelopmental Input

Cost Overruns


New Product Design

Logical Manufacturing Progression


New New Product Product DesignDesign

Drawing Review

POR/PFMECA/ESDI/DFX

Sheetmetal Processing

Machine Shop

Processing

Welding Shop

Processing

SSilk ilk SScreen creen PProcessingrocessing

Value-Add

Assembly

Class 10,000

Cleanroom

Value-Add

Assembly

Class 1000

Cleanroom

Process Control Validation (PCV)

SPC/FAI

Shipping

Project Lessons

Learned

Paint Shop

Processing

PCVPCV PCV

PCV PCV PCV

PCV

PCVPCV PCV PCV

Manufacturing Enhancements


78,000 Sq Ft Manufacturing Facility78,000 Sq Ft Manufacturing FacilitySheetmetalSheetmetal

Light out laser capabilities addedLight out laser capabilities added

QTY 9, AMADA Press brakes, multiple LASER and Punch PressesQTY 9, AMADA Press brakes, multiple LASER and Punch Presses

Machine ShopMachine Shop

Qty 7, 3-AXIS Vertical Mills, Qty 7, 3-AXIS Vertical Mills,

Qty 1 (Lathe) CNC turning CenterQty 1 (Lathe) CNC turning Center

• 14 weld stations – some dedicated work stations to support 4LPM & 2LPM 14 weld stations – some dedicated work stations to support 4LPM & 2LPM projects addedprojects added

• Both Powder and Wet coat paint booths can support up to 16ft tall frames,Both Powder and Wet coat paint booths can support up to 16ft tall frames,

• Material KAN-BAN inventory Material KAN-BAN inventory

• Onsite rework team for real time change controlOnsite rework team for real time change control

• 90 day strategic plan in 90 day strategic plan in progressprogress for a fully functional ISO 7 CL 10,000 for a fully functional ISO 7 CL 10,000 Value-Add Cleanroom.Value-Add Cleanroom.

Enhanced Machine Shop Capabilities


More MachinesMore Machines

Better Process ControlsBetter Process Controls

More CapacityMore Capacity

Project Success Criteria


Multiple Frames developed in Parallel with Optimum Success Criteria

Ramp to meet customer demand in less than 30 days.

Dedicated work stations through entire process to support both projects

PFMECA conducted and reported.

Added dedicated project weld stations.

Daily CFT and project timeline updates.

JIT raw material and procured materials inventory.

Tab and Key tubing design and fixturing for better welding controls.

Incorporated Value-Add materials in ISO 8 cleanroom during production.

Process Control Validation and OMS documented.

Multiple ESDI and customer design changes cut-in before and during development.

Onsite rework and ESDI participation with customer Engineering team eliminated costly logistics burden.

Imperial material solution provided during production when European metric material supplier failed to deliver attributed to ESDI, CFT’s and PR reporting.

100% Product Yield

Participated in crate recycling program to reduce logistics burden.

Lessons Learned and reported.

Product Transfer Services to LCR


l • S. Korea

• Singapore

• Malaysia

• Europe

• China

• Canada

• Mexicali, Mexico

Value Add Assembly & CleanroomIs the Next Logical Step In Manufacturing


Com

ing

soon

!!!

Summary


Cortec considers your company a valued partner and would like the opportunity to review your design and provide

The proposed ESDI solution is for an assigned project or Technical P.M. to work as an adjunct member of your Engineering team, Quality team, Supply Base Management or other groups as required.

Machine Shop capacity has increased with better controls and could be a stronger strategic resource to an existing partnership.

Welding and Large Frame Capacity has increased with better controls.

Multiple Frame projects with value-added assembly with 100% yield SPC, FAI process validation, and OMS documented and reported; benefits all Cortec customer base.

Strategic plan in progress to provide a Class 10,000 cleanroom for increased Value-Added assembly service in 90 days.

Streamlined communication to correct personnel at Cortec for better responsiveness.

Product Transfer Services to Low cost Region

Early Supplier Developemental Input

Documents

Transcript of Early Supplier Developemental Input