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Getting Additive Manufacturing Ready for Large Volumes Peter Hoogerhuis Philips Healthtech March 4 th , 2015

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  • Getting Additive Manufacturing Ready for Large Volumes Peter Hoogerhuis Philips Healthtech March 4th, 2015

  • March 4th, 2015 Philips Healthtech

    Introduction

    Tungsten 3D printing

    Application meets technology

    Large volumes

    Process

    Lean Manufacturing

    Practices

    2

  • Philips Healthtech

    34% Imaging Systems

    28% Customer Services

    6% Healthcare Informatics, Solutions &

    Services

    32% Patient Care &

    Monitoring Solutions

    37,000+ people worldwide in 100+ countries

    9.2 billion sales in 2014

    450+ products and services in 100+ countries

    9% of sales invested in R&D in 2014

    1 Based on sales last 12 months December 2014

    3 March 4th, 2015 Philips Healthtech

  • Making a difference in health

    1,000,000 patients monitored in their homes every day

    in emerging markets around the world now have access to Philips diagnostic imaging

    190 million patients tracked with our patient monitors last year

    100+ years of listening deeply to customers to understand what really matters

    4 million+ people sleep and breathe easier using our sleep aids

    +970 million people 10 petabytes of data managed for health care providers

    Present in

    100 countries with 450+ products and services

    4 March 4th, 2015 Philips Healthtech

  • March 4th, 2015 Philips Healthtech

    Smit Rntgen Part of Philips Healthtech Business Unit Generators, Tubes & Components Leading OEM grid supplier Founded in 1930s R&D Manufacturing Sales Located at Healthtech Campus in

    Best, The Netherlands Serving both healthcare and

    non-healthcare customers.

    5

    www.smitroentgen.com

  • March 4th, 2015 Philips Healthtech

    Tungsten 3D printing

    History Started in 2007

    Joint development with EOS

    Post processing development

    Platform separation

    Surface treatment

    Product verification & qualification

    equipment

    Equipment 2 Tungsten Laser Powder Bed Fusion

    printers

    Platform separation equipment

    Laser marking

    Optical, tactile and X-ray quality

    inspection tooling

    6

    Tungsten service provider

  • March 4th, 2015 Philips Healthtech

    Laser Powder Bed Fusion process

    Laser Powder Bed Fusion

    Post Processing Quality

    Assurance

    Powder Recycling

    3D CAD File

    7

    Separation

  • March 4th, 2015 Philips Healthtech

    Impression of facility and process (shots van movie: this powerpoint version does not contain the movie)

    Tungsten Additive Manufacturing (Movie)

    8

  • March 4th, 2015 Philips Healthtech 9

    Application meets technology

  • March 4th, 2015 Philips Healthtech

    Cross-section

    Scattered x-ray

    10

    X-Ray Physics

  • March 4th, 2015 Philips Healthtech 11

    Real World Requirements

  • March 4th, 2015 Philips Healthtech

    Capabilities

    Material: Pure tungsten (melting temperature 3420oC)

    Thinnest Wall thickness < 100mu

    Dimensional accuracy < 25mu

    Density up to 97-98%

    Build platform 23x23x20cm

    ISO 13485 certified

    Prepared for large volume manufacturing

    10000-40000 pc/yr

    12

  • March 4th, 2015 Philips Healthtech

    Large volumes

    Robust processes:

    3D printing

    Metrology

    Post Processing

    Lean manufacturing (ORP):

    13

    Layout

    Process

    Takt Time

    Work Sequence

    SOP

    Sustain

    1

    2

    4 4

    5

    6

    Balance

    Kaizen 7

    3

    7 steps to standard work

    Compliancy

  • March 4th, 2015 Philips Healthtech

    Robust processes: 3D printing

    Powder development

    Optics and mechanics

    Process settings

    Long term behavior

    Material characteristics

    14

  • March 4th, 2015 Philips Healthtech

    Robust processes: Metrology

    Tactile

    Optical

    X-ray

    15

  • March 4th, 2015 Philips Healthtech

    Robust processes: Post Processing

    Platform separation

    Surface treatment

    Heat treatment

    Machining

    16

  • March 4th, 2015 Philips Healthtech

    Compliancy - Quality System Requirements ISO13485 FDA 21 CFR Part 820

    17

    Master Validation Plan

    Each manufacturer shall establish and maintain a quality system that is appropriate for the specific medical device(s) designed or manufactured, and that meets the requirements of this part.

    Identification and traceability

    Calibration

    Process Validation

  • March 4th, 2015 Philips Healthtech

    Lean manufacturing: Process Takt Time

    18

    Takt Time: Customer demand production rhythm

    Available production time Customer demand

    Layout

    Process

    Takt Time

    Work Sequence

    SOP

    Sustain

    1

    2

    4 4

    5

    6

    Balance

    Kaizen 7

    3

    7 steps to standard work

    TT TT TT TT TT

    TT =

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  • March 4th, 2015 Philips Healthtech

    Lean manufacturing: Layout Balance Work sequence

    19

    Layout: U-shaped process/product flow

    Cell design (multiple work spots within short distances) Still room for growth

  • March 4th, 2015 Philips Healthtech

    Lean manufacturing: Layout Balance Work sequence

    20

    Balancing: Long Cycle Times (CT) towards short Takt Time (TT)

    Operator availability Short process-operator interval Handling multiple workspots in balance

    0

    10

    20

    30

    40

    50

    60

    70

    EOS Laser Marking EDM Inspection

    Min

    utes

    Yamazumi - balancing

    CT

    TT

    One piece flow impossible Batch production

  • March 4th, 2015 Philips Healthtech

    Lean manufacturing: Layout Balance Work sequence

    21

    Work sequence: Device Master Record (DMR) Customer specific

    Manufacturing Execution System (ORP) Work sequence based on part number Identification, Tracking & Tracing of parts Reporting

    Multiple customers Multiple parts Multiple machines

  • March 4th, 2015 Philips Healthtech

    Lean manufacturing: SOP Sustain - Kaizen

    22

    SOP - Standard Operating Procedures Describes the best practice Starting point for continuous improvement

    Sustain & Kaizen Kamishibai DMAIC

    Layout

    Process

    Takt Time

    Work Sequence

    SOP

    Sustain

    1

    2

    4 4

    5

    6

    Balance

    Kaizen 7

    3

    7 steps to standard work

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  • March 4th, 2015 Philips Healthtech

    Robust processes & Lean Manufacturing: Enablers for short design cycles

    Customer CAD drawing

    Manufacturing CAD drawing

    Slicing and verification

    Job preparation and building

    23

    Measurement and evaluation

  • March 4th, 2015 Philips Healthtech 24

  • March 4th, 2015 Philips Healthtech 25

  • March 4th, 2015 Philips Healthtech

    26

  • March 4th, 2015 Philips Healthtech 27

  • March 4th, 2015 Philips Healthtech

    Take-aways

    Additive metal manufacturing .... beyond the stage of rapid prototyping

    . prepared for large volumes

    Lean manufacturing . principles are directly embedded during production ramp-up . standard work for large volumes . eliminate waste and optimize added value

    In-house inspection tooling, measurement equipment

    . needed for fast feedback, short design cycle

    Monitor your business case . impact of post-processing

    28

  • March 4th, 2015 Philips Healthtech 29

    www.smitroentgen.com

  • Thanks for your attention

    www.philips.com www.smitroentgen.com

    [email protected]

    Getting Additive Manufacturing Ready for Large VolumesPeter HoogerhuisPhilips HealthtechMarch 4th, 2015Slide Number 2Slide Number 3Slide Number 4Smit RntgenTungsten 3D printing Laser Powder Bed Fusion processTungsten Additive Manufacturing (Movie)Application meets technologyX-Ray PhysicsReal World RequirementsCapabilitiesLarge volumesRobust processes:3D printingRobust processes:MetrologyRobust processes: Post ProcessingCompliancy - Quality System RequirementsISO13485 FDA 21 CFR Part 820Lean manufacturing:Process Takt TimeLean manufacturing: Layout Balance Work sequenceLean manufacturing: Layout Balance Work sequenceLean manufacturing: Layout Balance Work sequenceLean manufacturing:SOP Sustain - KaizenRobust processes & Lean Manufacturing:Enablers for short design cyclesSlide Number 24Slide Number 25Slide Number 26Slide Number 27Take-aways Slide Number 29Slide Number 30