development process (3.2.3) process owner presentation
DESCRIPTION
Development Process (3.2.3) Process Owner Presentation. Cal-Comp USA 4-23-2012. Cal-Comp USA. Employees - 500 (San Diego, Indiana & Reynosa) AS9100, ISO/TS 16949 (Automotive), ISO 9001 & 13485 (Medical) Aerospace & Military Customers:. 2. Process Overview / Criteria. 3. - PowerPoint PPT PresentationTRANSCRIPT
Development Process
(3.2.3) Process Owner PresentationCal-Comp USA
4-23-2012
Accelerating Supply Chain Performance
Cal-Comp USA
2
Employees - 500 (San Diego, Indiana & Reynosa)
AS9100, ISO/TS 16949 (Automotive), ISO 9001 & 13485 (Medical)
Aerospace & Military Customers:
Accelerating Supply Chain Performance
Process Overview / Criteria
3.2.3 Development Process How does your organization design and develop
new products or services? How are advanced techniques such as Six Sigma,
Design of Experiments, Design to Cost, Design for Manufacturability integrated into your operations?
How are customers and suppliers integrated into your development process?
How is the development process reviewed and improved?
3
Accelerating Supply Chain Performance
Our Key Practices
4
Advanced Product Quality Planning-APQP (Design For Six Sigma-DFSS)
AS9100 7.0 Product Realization 1.3.1 New Product Start-Up Process (APQP)
Development Process 3.2.3 Production Preparation Process 3-P Production Part Approval Process & FAI
Accelerating Supply Chain Performance
Things We Did Right
5
Customer-focused Multi-disciplined Teams Developed at 1st Engagement With Champions
Program Manager Manufacturing / Quality Engineer Test Engineer Value-Stream Manager Production Planner Procurement Specialist Cell Leads Key Supplier Representatives
Accelerating Supply Chain Performance
Things We Did Right
6
Concept Initiation / Approval
Program Approval
LP- Lab Prototype
(Proto)
MP- Mfg. Prototype
(Pilot)
PP- Production Prototype (Launch)
Feedback Assessment &
Corrective Action
Product & Process
Validation
Process Design &
Development Verification
Product Design &
Development Verification
Plan & Define
Program
Planning Planning
Product Design & Dev.
Process Design & Development
Product & Process Validation
Production
Feedback Assessment & Corrective Action
Advanced Product Quality Planning Time-Line
Accelerating Supply Chain Performance
Built Quality In With Core Tools
7
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Process Flow Diagram
Process Failure Mode Effects Analysis
QualificationControl Plan
Customer Requirements
Special / Key Product
Characteristics ( )
Install Antenna matching CCA with screw, lock washer and flat washer. Align pin in the center of the pad as possible - see pictures. Torque to 1.7in.lb.
Hand solder pin to the pad with no-clean Kester #245 Sn63/Pb37.
Work Instruction
Install Antenna matching CCA with screw, lock washer and flat washer. Align pin in the center of the pad as possible - see pictures. Torque to 1.7in.lb.
Hand solder pin to the pad with no-clean Kester #245 Sn63/Pb37.
Work Instruction
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Process Flow Diagram
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Input orOutputBlocks
InstructionalBlocks
DecisionBlocks
Start
SubroutineBlocks
(i.e. Rework)
Input orOutputBlocks
End
No
Yes
Process Flow Diagram
Process Failure Mode Effects Analysis
Process Failure Mode Effects Analysis
QualificationQualificationControl PlanControl Plan
Customer Requirements
Special / Key Product
Characteristics ( )
Customer Requirements
Special / Key Product
Characteristics ( )
Install Antenna matching CCA with screw, lock washer and flat washer. Align pin in the center of the pad as possible - see pictures. Torque to 1.7in.lb.
Hand solder pin to the pad with no-clean Kester #245 Sn63/Pb37.
Work Instruction
Install Antenna matching CCA with screw, lock washer and flat washer. Align pin in the center of the pad as possible - see pictures. Torque to 1.7in.lb.
Hand solder pin to the pad with no-clean Kester #245 Sn63/Pb37.
Work Instruction
Accelerating Supply Chain Performance
DFMEA & PFMEA Benefits
8
Design Failure Mode Effects Analysis - DFMEA Design For Cost Reduction - DFCR
Process Failure Mode Effects Analysis - PFMEA Design For Manufacturability - DFM Design For Assembly - DFA Design For Test - DFT Design For Serviceability – DFS Mistake-proofing & Process Controls
Accelerating Supply Chain Performance
Concept Initiation / Approval
Program Approval
Prototype Pilot Launch
Feedback Assessment &
Corrective Action
Product & Process
Validation
Process Design & Development
Verification
Product Design & Development
Verification
Plan & Define
Program
Planning Planning
Product Design & Dev.
Process Design & Development
Product & Process Validation
Production
Feedback Assessment & Corrective Action
PLAN
DO
ACT
CHECK
PLAN
DO
ACT
CHECKPLAN
DO
ACT
CHECK
PLAN
DO
ACT
CHECK
PLAN
DO
ACT
CHECK
PLAN
DO
ACT
CHECK
Multiple PDCA Experiments
Accelerating Supply Chain Performance
Begin Lean With 3P At Prototype
10
10
9
8
7
6
5
4
3
2
1
Operation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Min. 7.50 9.00 8.25 7.50 8.50 7.30 7.70 8.60 9.00 8.00 8.00 8.00 9.00 9.00 7.83
Note: Each color represents a different operator’s work cycle
3P - Production Preparation Process
Accelerating Supply Chain Performance
VSM From Raw Material to USAF
11
CUSTOMER LOCATIONS
LONG -LEAD ITEMS USAFRAW
ALUMINUM SUPPLIER
CUSTOMER LOCATIONSSEICUSTOMER
LOCATIONSCCUSACUSTOMER LOCATIONSADC
SHIPPED AS
AS NEEDED
SHIPPED AS 1x DAY
SHIPPED AS 1x DAY
FINISHEDGOODS
SHIPPED AS WEEKLY
ADCPRODUCTION
CONTROL
SEISALES ORDER
BANK
CCUSAPRODUCTION
CONTROL
100 Day100 Day 100 Day100 Day100 Day100 Day
Accelerating Supply Chain Performance 12
Continual Improvement
Accelerating Supply Chain Performance
Things We Learned
13
Empowered Customer-focused Multi-disciplined Teams – Main Ingredient for Success
Product & Process Intimacy – Well Worth the Effort Core Tools - Living Records of Our Very Best 3P & APQP Work Hand-in-glove – Quality, Cost
Reduction & Productivity Improved Together Preventing Problems (Mistake-proofing) & Removing
Waste in Advance – Smooth & Successful Launches Improved DFX Capabilities – More Value-added
Services for Our Customers Ultra Effective Ramps – More Like Step-functions
Accelerating Supply Chain Performance
Questions
14
Thank YouContact: Kenny Heifner
(858) 587-6960