Presented by: Chantelle Phillips HellermannTyton SA ... · • Project Management • Timing...

P r e s e n t e d b y : C h a n t e l l e P h i l l i p s H e l l e r m a n n Ty t o n S A E n g i n e e r i n g

1 9 J u l y 2 0 1 8

GEM INNOVATE • COLLABORATE • STANDARDIZE

INNOVATE • COLLABORATE • STANDARDIZE GEM

HellermannTyton South Africa is a subsidiary of the HellermannTyton Group which has operations globally in 37 countries, employs over 4000 people and generates revenue in excess of 700 million Euro We have also part of the international design & innovation team (Only 5/37) – Germany, France, UK, USA and now SA Product Design, Development and Manufacturing is a key focus and the local facility utilising state-of-the-art CNC machines, plastic injection moulding machines, extrusion machines and printing equipment to produce world class products in compliance with international quality standards

DRIVEN BY HTSA ENGINEERING TEAM


GLOBAL PLAYERS

December 2015 taken over by Delphi automotive – Headquartered in UK, it is on of the world‘s largest automotive parts manufacturers

A Web-based Product Data Management (PDM) system that supports geographically dispersed teams while managing critical processes such as content, change and configuration management. This allows you to create and manage product structure views such as “As-Designed” and “As-Planned,” thereby optimizing configuration management. Features and Benefits Global access — Enables Web-based access to a current product data management repository Seamless connections — Enables access to multiple mechanical/electrical CAD applications, embedded software tools, desktop applications and ERP systems Prevents design errors — Controls and automates product development processes, improving quality and reliability Improved innovation — Facilitates rapid development of new products with powerful configurations tools Complete integration


Head office facility

Head Office – Linbro Business Park

- Site – 22,000 m² - Offices – 2,800 m² - Manufacturing – 4,700 m² - Warehousing & Logistics – 5,600 m²


Experience & Expertise

Our local engineering staff have been involved in the tooling & plastic injection mould manufacturing in the Automotive industry for over 40 years

Merged with HellermannTyton in 2015

HTSA Engineering is committed to continual improvement as a basic philosophy for achieving competitive and efficient manufacturing of world class products

The ability to draw on HellermannTyton Group’s world-renowned experience in the innovative

design, development and manufacture of specialised plastic parts, gained over numerous years of successful operation around the globe


Tool Room Equipment

State-of-the-Art Precision Engineering Equipment 2 x NC Spark Eroders 2 x CNC Spark Eroders 1 x Wire Cutter 3 x 3 Axis CNC Milling Machines 1x 4½ Axis CNC Milling Machine 2 x Surface Grinders 2 x CNC Lathes 2 x Heat Treatment Furnace 1 x Mechanical Saw 4 x Pedestal Drilling Machines 4 x Conventional Milling Machines 1 x Conventional Lathe 1 x Hardness Tester


Tooling Capability

Small to Medium size tooling (up to 3 tons); Plastic injection moulds; Sheet metal progression tooling; High pressured aluminium die cast moulds; Jigs and checking fixtures; Special purpose machinery; Prototyping; Product design and development; Tool Design & Manufacturing Process/Assembly line design All types of tooling Manufacturing efficiency improvements Technical Consulting & assistance CAD/CAM DESIGN & CNC SYSTEM

SOFTWARE: Creo Solidworks 2017 Mastercam 2018


CONDITION for industry to place orders on SA

1. Contract with Full Service Provider ‒ Project Management - One face to Client

2. Tool Design (Right first time) 3. Delivery (Lead times, commitment dates) 4. Cost (Internationally Competitive) 5. Quality (Internationally competitive) 6. Manufacturing / Volume Capacity


Concept

Simulation

Design Review

Identify critical areas

CAD & 2D conversion

Distribute Commission,

PPAP, Handover

Clustering - process flow

PM Timing Cost Mng Risk Mng Metrology Reporting

Trails & Optimisation Trails & Optimisation


RFQ

• Based on customer specific requirements • Based on tool manufacturing standards – International Automotive • Fully broken down package with all tool systems • NDA’s & Manufacturing agreements


Trimming tools Mechanical/Hydraulic Orientation Cavities Post processing Machining Jigs Flow analysis Core pulling

Fixture type: Pneumatic Mechanical Component sensing modules

Hot Runner Mould flow analysis Core pulling Semi/Full automatic Post processing Assembly Orientation of com- ponents and cavities

Tool line-up Blanking tools Forming tools Progressive tools

SHEETMETAL PLASTICS JIGS & FIXTURES

ALUMINIUM CASTINGS

Concept – tooling type (Exactly how the tool will work) – conceptual design of mould






SIMULATION

• Mould flow analysis • Prototyping • DFM


DESIGN REVIEW

Customer Designers (Selected board) Process Engineer SQA Engineer APQP process followed from project kick off (Advanced Quality Prod planning) Identification of critical areas and allow for optimisation in design Could have numerous design reviews for downstream processes


MOULD/TOOL DESIGN 2D DRAWINGS SPECIFYING TOLERANCES & SPECIFICATIONS

• 2D drawings to be prepared with tolerances • Include full process instruction, materials to be used, stress relieving etc • Full metrology report

• Distribution of work amongst toolmakers


CLUSTER MANAGEMENT

• Project Management • Timing Management • Cost Management • Risk Management • Full understanding of all Quality Systems & Processing requirements • Assist with ISO 9001 implementation • Metrology of critical sizes • Upskilling – get all to work the same • Supplier development • Report management – Design review team


CLUSTER MANAGEMENT


MANUFACTURE

Facilities will be audited to work to quality standards that comply with Automotive requirements Processes to be monitored Timing plans to be updated and communicated to customer with visual reports


Visual Progress Reporting – Example 1


TOOL TRAILS & OPTIMISATION

This will happen at nominated toolmaker/1st tier supplier for part trails & provide 1st set of parts for measurement and fitment Every project will accommodate for at least 2 loops of optimisation to allow 100% dimensional accuracy still within required timing

COMMISSIONING & HANDOVER • Process Engineers to ensure optimum production parameters set and process is constant • Dimensional reports on product • Allow easy fault finding after commissioning if problem found with mould (Processing

parameters, tool inspection or material issues) • Critical component list (spares) to be supplied (Hot runner elements, thermocouple, ejector pins

etc) • Maintenance


IMPACT (VALUE)

Economic Growth Localisation Job Creation Job retention Growing of industry Upskilling industry Local toolmaking support for OEM’s


SUCCESSES – MBSA BRACKET TOOL LOCALISTION


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Mercedes Benz (Cable Duct Inner RH & LH)

New 1st Tear supply to MBSA In-house mould design & Manufacture Collaboration – UTP – fastrack mould manufacture with advanced machined mould

base Vehicle fitment for jig (Poke yoke) Limit switch activation on assembly of pin – clamps & locks part in place Parts move down the shoot and are packaged accordingly All on one line assembly


SUCCESSES – MBSA BRACKET TOOL LOCALISTION


TOOL 3D MEAUREMENT REPORT - UTP


PART 3D MEAUREMENT REPORT


RESULT

• World-class timing (12 weeks) • World-class quality (Through hardened) • World-class Costs • Cluster collaboration & Management • Localisation (APDP benefits) • Job creation


NEXT STEPS

Create Volume Capacity Pool knowledge Supplier Audits


AUDIT – NEW STANDARD

Design capabilities Machining capabilities Project Management (delivery times) Costing structures Machining processes Machine maintenance – e.g Backlash checked on machines Quality management – dimensional reports of previous projects Management system Internal go/no go processes


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New Export moulds for HTG – Production Poland

1st Project with HTG

NOW: Exporting moulds for group


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After 1st project with HTG

Over 40 projects quoted. 8 orders received since February 2018 – further 7 PO’s in progress Capacity planning being conducted to grow local capacity Money stays in the group Over R 300 million quoted in tooling


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Current project & Collaboration – Clustering UTP

NOW: Exporting moulds for group in production


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With industry’s support output has doubled

In progress


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Advanced machined Custom mould in parallel production


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Fast track turnaround times


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Growing capacity

Group benefits by production in SA

Clustering of local toolmakers – finishing capabilities Designs to remain with HTSA Engineering Project Management to stay within HTSA Engineering Increase volume capacity Single face to the customer Supplier development & Upskilling Local incentives Local content kickbacks for OEMs

WORKING TOGETHER WE CAN MAKE A DIFFERENCE!!!

Current annual South African tooling market worth R18 billion Only 12% produced locally

ANY QUESTIONS?

THANK YOU

Chantelle Phillips

Technical Projects Manager [email protected]

+27 79 504 1474

mailto:[email protected]

Presented by: Chantelle Phillips HellermannTyton SA ... · • Project Management • Timing...

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