additive manufacturing in the spare part supply chain (bouke wullms)
Post on 13-Aug-2015
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Contents
Does additive manufacturing change the supply chain of Philips Healthcare?
What is additive manufacturing
Additive manufacturing in the spare part supply chain
Thesis
Results and conclusions
Further research
Technology development
Invention by Chuck Hull
Stratasys
1986 1989 2007
First consumer 3D printing
First patent expires
2009 2014
Increased adoption in:• Medical• Aerospace• Automotive
3D systems
2012
Increase in attention
Development, Rapid prototyping
AM in the spare part supply chain
Additive manufacturing offersProduction on demandProduction on location
AM in the spare part supply chain
Main objective in current service supply chains – obtain the highest possible service levels at the lowest possible costs
high inventory costs and transportation costs
We want:• No inventories• Small batch sizes• Local production
Current supply chains
Mass production
Global supply chains
High complexity
3D printing
Spare parts characteristics
Low demand rates
Required locally
Critical response times
Thesis
Application of additive manufacturing in the spare parts supply chain
Selection of spare parts
Model for additive manufacturing in the last time buy process
Philips HealthcareMedical systems for hospitals
These systems are• High tech• Complex• Expensive• Used for many years• Service contract
Selection procedure
Technical criteria
Materials: plastics & metals
Max dimensions plastics 2100 x 700 x 800 mm
Max dimensions metals 550 x 550 x 750 mm
No electronic components
Economic criteria
High value High inventory level Low demand rate (slow moving parts)
Long lead time High Minimal order quantity (MOQ)
Target group
Small Slow moving Plastic or metal Mechanical spare parts
Preferably:– complex geometries– high MOQ– “under the hood parts”
Pins, covers, grips, and cooling vents
c c
AM in the last time buy processLast time buySupplier stops production
– Service contract with the customer– Large order– Safety stock– High inventory costs
Additive manufacturing– Print on demand– Reduce inventory– Eliminate last time buy– Use a 3D printing service provider
Mathematical model
Production +/- 10 year service only
Service period
End of Production (EOP) End of contract (EOC)
New product introduction (NPI)
ModelMinimum expected costs
Order up to level at the LTB moment
Inventory level using additive manufacturing
Model resultsResults
– Reduced order up to level– Lower inventory required– Cost savings
Replacement of the safety stock
When additive manufacturing becomes cheaper, the inventory can be reduced further and more parts should be produced using additive manufacturing
ConclusionsAdditive manufacturing suitable for
– Small, slow moving mechanical spare parts
Limited scope of AM: Small portion of spare part portfolio
No replacement of current technologiesFocus on added value
Cost savings in the last time buy decision through inventory reduction
Rapid technology developments
Costs of AM are decreasing, so benefits will increase in future
RecommendationApply additive manufacturing in last time buy process
– Cost savings– Build experience with AM
Gradually extend the use of AM in the coming years
Further researchQuality standards of additively manufactured parts
Redesign of spare parts using additive manufacturing
Additive manufacturing when no molds are available anymore– Reversed engineering
Insourcing vs outsourcing
Network design
Intellectual property rights and liability issues
Build processes• Additive manufacturing is a collective term for all processes that built up products
layer by layer
– Material extrusion– Vat photopolymerization– Powder bed fusion– Binder jetting– Material jetting– Sheet lamination– Directed energy deposition
Material extrusionMaterial dispensed through nozzleBasic process in consumer 3D printingPlastics
Advantages– Most used– Widely available– Relatively cheap
Disadvantages– Slow– Weak parts– Rough surface finish
Applications– Consumer 3D printing– Prototyping– Low volume production
Vat photopolymerizationVat filled with liquid resinLight source hits the liquid surfacePlastics
Advantages– High resolution– Smooth surface finish
Disadvantages– Post processing– Support structures– Weak parts
Applications– Prototyping– Jewelry– Mockups
Powder bed fusionPlatform filled with powderLaser melts powderConsidered best technology for industry applicationsMetals and plastics
Advantages– Strong metal parts– Fast– No support structures
Disadvantages– High costs– Lack of surface quality– Post processing
Applications– Medical: Implants– Aerospace: End parts
Binder jettingLiquid binder material sprayed on powderTraditional inkjet printingPlastic, metal, glass, sand ceramics
Advantages– Full color parts– Inexpensive
Disadvantages– Weak, not durable– Post processing
Applications– Prototyping– Tooling
Material jettingDroplets of material are sprayed on the build platformMaterials is hardened with UV lightPlastics
Advantages– Multiple materials– Very precise– Smooth surface
Disadvantages– Low durability– Support material– Post processing
Applications– Prototyping– Mockups – Jewelry
Sheet laminationBonding layers of sheetsCut the sheet in desired formPaper, plastic, metal
Advantages– No heat– Embed wires– Fuse different materials
Disadvantages– No complex shapes– Weak
Applications– Testing – Tooling– Low complex parts
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