purchase of electronic components from the far east p r o ......• reliability testing according to...
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P R O G N O Z A
Purchase of electronic components
from the Far East
Toruń, 21st June 2010
Import from Chinese People’s Republic to EU countries
74 63282 000
90 148106 220
128 590
160 327
194 932
232 620
247 916
7,5%8,4%
9,6%
11,4%
12,5%13,6%
14,4%
16,2%
17,4%
15,8%
0
50 000
100 000
150 000
200 000
250 000
300 000
2000
2001
2002
2003
2004
2005
2006
2007
2008
1H20
09
0%
2%
4%
6%
8%
10%
12%
14%
16%
18%
20%
Import value of EU countries from ChPR (m EUR) Share of import of EU countries from ChPR in total import (%)
Trade between Poland and Chinese People’s Republic in 2009 was in value of 11 bn EUR, where the import to Poland wa s in value about 10 bn EUR.
Increase of unit labour cost in the world
World market shares of high-tech products
Forecast of the share in the world PKB
Geographical structure of purchases
Total purchases of Grupa Apator in 2009 were 121 m P LN
Total purchases of Apator in 2009 were 40 m PLN
Europe24%
Home66%
Far East10%
Far East
15%
Home
63%
Europe
22%
Apator SA
Non-ferrous products
1%
Electronicts54%
Electrical engineering
41%
Plastic products2%
Other materials w ith products on
iron alloy2%
Share in purchases in the Far East
Grupa Apator
Non-ferrous products
23%
Electronics28%
Electrical engineering
21%
Plastic products
1%
Other materials
w ith products on
iron alloy27%
30%
40%
50%
60%
70%
80%
90%
100%
110%
kwiec
ień
200
5cz
erwiec
200
5sie
rpie
ń 2
005
paździe
rni k
200
5gr
udzie
ń 2
005
styc
zeń
200
6m
arzec
2006
maj
2006
lipiec
200
6wrz
esień
200
6lis
topa
d 20
06sty
cze ń
200
7m
arze
c 20
07m
aj 2007
lipi e
c 20
07wrz
esień
200
7lis
topa
d 200
7sty
czeń
200
8
GW 12EA5 - 1 fazowy GW 16EC3 - 3 fazowy
Changes in costs of materials of electronic elements for electronic electricity meters - GW type meters
GW type meter
till 07.2005 Memec’sdisplay was used
in 08.2005 chinese display was introduced
in 10.2005 1-circuit boardmeter was introduced
in 12.2005 meter with fieldsensor was introduced
40%
50%
60%
70%
80%
90%
100%
110%
mar
zec 2
008
kwi e
c ień 20
08m
aj 20
08
czer
wiec 2
008
lipiec
200
8
sierp
ień
200
8
wrzes
ień
200
8
paźdz
iern
ik 2
008
l istop
ad 2
008
grudz
ień
200
8sty
cze ń
200
9lu
ty 200
9m
arze
c 200
9
kwi e
c ień 20
09m
aj 20
09
czer
wiec 2
009
lipiec
200
9sie
rpie
ń 2
009
wrzes
ień
200
9
paźdz
iernik
200
9l is
topad
200
9
grudz
ień
200
9sty
cze ń
201
0lu
ty 201
0m
arze
c 201
0
kwiec
i eń
2010
GR 12EA5 - 1 fazowy GR 16EC3 - 3 fazowy
GR type meter
In II and III quarters of 2008 1-circuit board was introduced
Changes caused by exchangerate of EUR and USD at the turnof 2008
Changes in electronic material costs for electronic electricity meters – GR type meters
three phase meters
80,00
100,00
120,00
140,00
160,00
180,00
200,00
220,00
240,00
260,00
280,00
1Q20
052Q
2005
3Q20
054Q
2005
1Q20
062Q
2006
3Q20
064Q
2006
1Q20
072Q
2007
3Q20
074Q
2007
1Q20
082Q
2008
3Q20
084Q
2008
1Q20
092Q
2009
3Q20
094Q
2009
1Q20
10
Prices of GW and GR type electronic electricity meters
one phase meters
40,00
50,00
60,00
70,00
80,00
90,00
100,00
110,00
1Q20
05
2Q20
05
3Q20
05
4Q20
05
1Q20
06
2Q20
06
3Q20
06
4Q20
06
1Q20
07
2Q20
07
3Q20
07
4Q20
07
1Q20
08
2Q20
08
3Q20
08
4Q20
08
1Q20
09
2Q20
09
3Q20
09
4Q20
09
1Q20
10
max price of competition min price of competition price of Apator
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
1-2Q2008 1-3Q2008 1-4Q2008 1Q2009 1-2Q2009 1-3Q2009 1-4Q2009
12EA5 GR 16EC3 GR
Changes in profitability of technical manufacturing costs of GW and GR type meters
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
9,0
10,0
1Q2005 1-2Q2005 1-3Q2005 1-4Q2005 1Q2006 1-2Q2006 1-3Q2006 1-4Q2006 1Q2007 1-2Q2007 1-3Q2007 1-4Q2007 1Q2008
12EA5 GW 16EC3 GW
Quality problems and economizing on purchasing in the Far East
Since 2007 occurred some quality problems of the di splays being delivered from Chinese manufacturer. Those displays were installed in mete rs since the August 2005 and they were delivered by the Polish distributor JM Elektronik in G liwice. The seller in the reference list informed that the Chinese manufacturer also had manufactured the displays for Citroen, Bosch, Samsung and Mitsubishi.In 2008 Apator SA brought a case to a court in ord er to get the compensation of the costs of repairs from JM Elektronik (latent defect). The witnesses we re examined and expert were selected by the court (from Warsaw University of Technology). In Ju ne 2010 experts took samples of the displays in order to give expert opinion.
6 113
10 303
4 000
5 000
6 000
7 000
8 000
9 000
10 000
11 000
2005 - 2009
Cost of the replacement of the displaysEconomizing on components
Purchasing process of electronic components
Preventive actions:
• quality control by reliability testing of the produ cts-procedure;
• auditing of manufacturers of electronic subassembli es – introduction of the complete identification of the components from the suppliers by bar coding (for instance Hanza, Sims);
• delivery of critical elements only from famous man ufacturers (for instance Texas Instruments, STMicroelectronics, Microchips T echnology Inc.)
The rules of cooperation with the Far East:
• the representative in Chinese People’s Republic whos e role is to make contacts with manufacturers and quality control of their pro ducts;
• the departure twice a year to audit the manufactur ers of subassemblies
Procedure of reliability testing of products and components
Reliability test procedure is used for:
• electronic components being used in electronic metering equipment,
• printed circuit boards being used in electronic metering equipment
Procedure defines detailed rules and
mode of proceeding in case of :
• acceptance of a new product for manufacturing,
• acceptance of substitute of electronic component for manufacturing,
• definition of requirements regarding reliability tes ting and additional special ones for selected electronic components,
• definition of the schedule for testing,
• statistic reliability testing for products
Procedure of reliability testing of products and components
1. Acceptance of a new product in respect of manufa cturing:• manufacturing the batch of samples in quantity defi ned by development department and subject them to routine testing and reliability tes ting;• manufacturing of pilot batch in quantity defined by salesmen and design engineers and subject them to reliability testing
2. Implementation of substitute – critical element:• acceptance by design engineers of technical paramet ers of components presented in catalogues ;• manufacturing the batch of samples: 10 units of the product and subject them to routine testing and reliability testing;• manufacturing of the pilot batch: 100 – 1 000 units of the product with components from the batch made by the supplier later than the batch for sample series and subject them to routine testing and reliability testing;• manufacturing of considerable manufacturing batch o f 1 001 – 10 000 units with components from the batch made by the supplier late r than the batch for sample/pilot series and subject them to routine testing and reliability testing
Products and components are subject to:
• testing according to the standard PN-ISO 2859-1:200 3,
• reliability testing according to PN-EN 62059-31-1 i ncluding testing of critical elements
Procedure of reliability testing of products and components
3. Implementation of substitute – standard component :• acceptance of technical parameters of components by design engineers presented in catalogues ;• design engineers make the decision whether it is ne cessary to carry out single electrical testing and what is to be the scope. After the acc eptance of components by design engineers the components are allowed to be used in serial ma nufacturing. However, the earliest possible time the components should be mounted in 3-5 pieces of the product and subject to reliability testing – negative result of reliability testing means the withdrawal the consent to use that component..
4. Testing of current manufacturing:• subject to testing of random selected samples not r are than once per month suitable to thesales volume and subject them to routine testing and reliability testing.
5. Elimination of critical elements of high mortali ty:• process engineers provide with complete identificat ions of critical elements being used in manufacturing of the products and therefore the dat a are archived: manufacturer of the component used,, number of batch, date of manufactu re, date of receipt to the warehouse, number of manufacturing batch of the products;• quality control personnel based on received quality claims and reliability testing carried out regularly inform design engineers and procurement p ersonnel about mortality of particular critical elements;• design engineers make the analysis of the mortality of critical elements and the reasons of their damages. Based on it they replace the critica l elements being used to those of higher parameters or they apply to procurement personnel t o change the supplier.
Control system - management
Integrated management system is based on the follow ing standards:
• PN-EN ISO 9001:2009 – quality,
• PN-EN ISO 14001:2005 – environment,
• PN-N-18001:2004 – Safety and Health at Work
Control system - MID
Possibility of certification of own products accord ing to Directive MID by the entities of Grupa that manufacture electricity meters:
• Pafal SA:
• since July 2008 - module B for 3-phase post paid me ters,
• since October 2008 – module D for 3-phase post paid meters,
• since April 2009 – module B for single phase post p aid meters,
• since February 2010 – module D for single phase pos t paid meters;
• Apator SA:
• since September 2009 – module B for single phase pr e-paid meters,
• since December 2009 – module D for single phase pre -paid meters,
• planned date of the audit for modules B and D for 3 -phase pre-paid meters is
September 2010Granting of module D gives the following possibilit ies:• Independent assessment on compliance of metrologic al and quality requirements of the meter being man ufactured without participation of Central Measurement Office (home sale) and to the countries of European Union ). This fact means the prestige and financial benefit since ther e are lack of fees for legalization taken by Central Measurement Office that reduce considerably the cost of manufac turing of the product.• Sale of certified product on all markets of the Eur opean Union without necessity to comply with additi onal requirements of the local measurement offices. The effect is also minimization of the time necessary t o comply all formal requirements in case of the export to Europe an Union countries.
Ratio of faults – manufacturers of electricity meters in Grupa Apator
0,32%
0,15%
0,30%
0,16%
0,11%
0,26%
0,05%0,11%
0,32%
0,19%
0,38%0,38%
0,21%
0,25%
0,27%
0,00%
0,05%
0,10%
0,15%
0,20%
0,25%
0,30%
0,35%
0,40%
2005 2006 2007 2008 2009
Metering equipment of Apator SA Total Apator SA Total Pafal SA
Ratio is calculated as the relation of the costs of manufacturing faults to revenues on sales
Organization structure of the quality control in Apator SA
Quality of Products Team of Inspectors1) checking the compliance with technical and design requirements:- in input warehouse ,- in manufacturing area of the parts,- in assembly area of electronic parts and switchgear ,- in warehouse for finished products
Measurements Team1) checking the compliance of the product,subassembly or part with the assumptions of:- obligatory regulations,- technical specifications,- design;2) verification of new suppliers
Product Testing Team1) quality verification of products and new suppliers by:- reliability testing ,- testing of current products;2) Testing of the software of the equipment;3) Testing of finished product
Calibration and Legalization Section1) checking of metrological compliance with the Regulation of Ministry of Economy
Service Team1) remedy of damages2) making motions regarding operation 3) taking quality (corrective) actions
Managing Director of Apator SA
Quality and Service Management Department
P R O G N O Z A Thank you for your attention
Toruń, 21st June 2010