working with oversea contract manufacturers - las vegas hardware meetup - may 19, 2014
DESCRIPTION
In this presentation, Dragon Innovation will provide an overview to working with oversea contract manufacturers. This presentation was given at the Las Vegas Hardware Meetup in My 2014. Topics will include: - Dragon Innovation Introduction - Product Development: The Old Way & The New Way - Decide Where to Build - Request for Quote / Contract Manufacturer Selection - Schedule - The Road to Production - Quality Share the presentation here: http://bit.ly/Overseas-Contract-Manufacturers About Dragon Innovation Dragon Innovation works with entrepreneurs to launch hardware products and scale companies. Founded by a team of hardware experts, Dragon provides a clear path from prototype through production with unmatched manufacturing expertise and trusted connections. Dragon's client roster includes Coin, MakerBot, LIFX, Scout, Romotive, Sifteo, Orbotix, FormLabs and over 100 more companies paving the road for how new technology gets made. Connect with Dragon Innovation Website: http://www.dragoninnovation.com Blog: http://blog.dragoninnovation.com Twitter: http://twitter.com/dragoninnovate Slideshare: http://www.slideshare.net/dragoninnovation/TRANSCRIPT
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DRAGON INNOVATION, INC. !
WORKING WITH OVERSEAS CONTRACT MANUFACTURES
!MAY 19, 2014
LV HARDWARE STARTUPS MEETUP| LAS VEGAS !!!!!
SCOTT N. MILLER | CEO | @DRAGONINNOVATE | WWW.DRAGONINNOVATION.COM
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No Need To Take Notes
http://bit.ly/Overseas-Contract-Manufacturers
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MIT RoboTuna
3
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Disney Dino
4
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My Real Baby
5
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Product Development !
The Old Way
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Build then Sell
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Agenda
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Arrgh!
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Agenda
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HARDWARE IS EXPLODING
Unprecedented periods of growth come with lots of chaos.
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DRAGON INNOVATION HAS HELPED LAUNCH AND SCALE OVER 100 COMPANIES SINCE 2009
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HARDWARE INNOVATION NOW COMES FROM THE LITTLE GUY Prototyping has never been easier thanks to 3D printing, Arduino, the Maker Movement
(all of these guys are Dragon clients)
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Product Development !
The New Way
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CROWDFUNDING IS FUEL ON THE FIRE
•Raise capital upfront •Validate product / market fit •Create engaged & passionate community early •Get the attention of media and investors •Understand build volumes
New transactional model is perfect for hardware
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But the promise of the hardware revolution faces an existential
threat.
75% OF CROWDFUNDED HARDWARE PROJECTS
DELIVER LATE OR NOT AT ALL
!!
PROF. ETHAN MOLLICK, UNIVERSITY OF PENNSYLVANIA / WHARTON
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•COGS & Tooling Estimation •DFMA •Funding Threshold Calculation •Production Strategy & Scheduling •Marketing Strategy •Connections
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STEP 1: DECIDE WHERE TO BUILD
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Examples to Talk Through
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China?
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Yes! Manufacture in China If Your Product... Is COGS (Cost of Goods Sold) sensitive
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Yes! Manufacture in China If Your Product... Requires higher production volumes (>10k units)
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Yes! Manufacture in China If Your Product... Requires significant manual labor to manufacture and assemble
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Yes! Manufacture in China If Your Product... Uses existing manufacturing technology (i.e. injection molding, etc)
http://berkeleysg.com
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Yes! Manufacture in China If Your Product... Is tolerant of variations in supply chain and logistics
http://berkeleysg.comhttp://kilterpulse.com
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Yes! Manufacture in China If Your Product... Can benefit from low cost Design for Manufacturing (DFM) Non-recurring Engineering (NRE)
http://berkeleysg.comhttp://kilterpulse.com
http://plasticstoday.com
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Yes! Manufacture in China If Your Product... Has “physically” protectable IP
http://berkeleysg.comhttp://kilterpulse.com
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China Drawbacks for Manufacturing
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China Drawback Significant Distance from USA
http://supplychaindigital.com
http://skeptically.orghttp://studentuniverse.com
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China Drawback Significant Language Barrier
http://supplychaindigital.com
http://skeptically.orghttp://studentuniverse.com
http://asiasociety.org
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China Concern Rising Exchange Rate
http://en.wikipedia.org
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USA?
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Yes! Manufacture in the US If Your Product... Requires low volumes
http://berkeleysg.comhttp://kilterpulse.com
http://www.theguardian.com
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Yes! Manufacture in the US If Your Product... Can be manufactured and assembled through automation
http://berkeleysg.comhttp://kilterpulse.com
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Yes! Manufacture in the US If Your Product... Is sensitive to shipping time and expense
http://berkeleysg.comhttp://kilterpulse.com
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Yes! Manufacture in the US If Your Product... Has difficult-to-protect IP
http://berkeleysg.comhttp://kilterpulse.com
http://www.independent.co.uk
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Yes! Manufacture in the US If Your Product... Requires non-standard capital equipment
http://scientificmachining.com
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Yes! Manufacture in the US If Your Product... Is part of a government contract
http://en.wikipedia.org
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STEP 2: REQUEST FOR QUOTE / CM SELECTION*
!
!
!*THE MOST IMPORTANT MANUFACTURING DECISION YOU’LL MAKE
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Overview of the CM Selection Process
http://en.wikipedia.org
1. Talk with trusted network connections who have manufacturing experience. 2. Create a differentiated list of 5 - 10 CMs. 3. Down select to 3 - 5 factories based on your product category (why?) 4. Create a Request for Quote (RFQ) Package. 5. Visit! 6. Analyze Results. 7. Negotiate Big Items. 8. Talk with the CM’s customers. 9. Select the winner, and leave the others on good terms.
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RFQ Package
http://en.wikipedia.org
•Company Overview -Team overview -Funding -Product -What’s done -What needs to be done -Factory Criteria
•BOM -Canonical format (A2A) in Excel -Transparent and Formula Driven -Separate Std, Special and Consigned Margins/Markups -Include all costs to Ex-Factory -Fill in the blanks
•Schedule -Gantt chart (Cloud) -Fill in the blanks
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Factory Visit Checklist
http://en.wikipedia.org
Do you like the team? Are they experienced and friendly? Do they have the right manufacturing capabilities? Does your intended volume match their volume capabilities? Are they financially stable? Do they have enough working capital to get going? Do they have favorable payment terms? Are they transparent in their costing? Do they take IP seriously? Did they show you something they shouldn’t have? Are they ethical in their treatment of their workers and otherwise? Do you have access to upper management? Are they excited about working on your product?
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CM Comparison (A2A Decision Matrix)
http://en.wikipedia.org
•Total Material Costs •Labor •Margins/Markup (Std, Special, Consigned) •Pareto of Top 5 Most Expensive Components •Fixed Costs (tooling, fixtures, NRE) •Schedule •Fit Criteria
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POP QUIZ
• Question: What is the biggest challenge in manufacturing ?
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Hint
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POP QUIZ
• Question: What is the biggest challenge in manufacturing?
• Answer: Communication! • You cannot design in a vacuum (even if you design
vacuums). Strong communication and teamwork skills are critical to success. Engineering is team sport. It’s all about the people. “Us” and “Them” won’t work.
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Communication At Work
Bi-Directional Knowledge Flow
Product Designed In U.S.A. Database Sent To Cm Tooling Manufactured
Parts Molded Product Assembled Final Inspection & Shipping
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Manufacturing Management Triangle
Quality
Cost
Schedule
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Cost of Goods Sold
(COGS)
• Direct costs for goods produced. • Does NOT include Tooling. • Actual price depends on where a
company takes ownership: - Ex-Factory (XF) - FOB (add overland transport to
XF) - Landed (add shipping to FOB) - Inventory (add warehousing)
• Price will vary by date depending on running changes, transportation costs, currency exchange, commodity costs, etc.
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Very Simple Retail Costing Model
$
Sell-Through Price (Retail Price)
Sell-In Price (Wholesale Price)
COGS
Retailer Gross Profit
Company Gross Profit
COGS
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COGS YOUR DESIGN
• Material and Component Selection
• Fabrication Method • Manufacturing Efficiency
(First Time Yield, machine tonnage, assembly labor, number of operations, etc.)
• Quality Requirements (driven by requirements / Voice of Customer)
• Packout (replaceable vs. rechargeable batteries; packaging; spares, etc.)
MANUFACTURING PARTNER • BOM Transparency • Profit Margin • Labor Rate • Currency • Geographic Location
(shipping, tariffs, etc.) • Capability (in-house vs.
outsourced) • Supply Chain (Purchasing
Power, volume (piggy back), Consigned vs Purchased, etc).
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Controlling Costs
1.Deconstruct the BOM. 2.Separate special components. 3.Transparency 4.Compare to standards. 5.NegoAate Inclusions
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Additional COGS Strategies
Cost
•Bill of Material Transparency: Require factories to provide an item by item costed BOM. No mysteries or hidden formulas.
•Calculate labor rates. Pop Quiz – How???
•Build a “Standard Cost” database. Price out cost reducJons.
•If Jme permits, develop relaJonships with mulJple vendors to avoid single source suppliers. Leverage is a beauJful word.
•When manufacturing in volume for a CE product, it is criJcal to understand and control COGS. Focus here! Because of the volume, every penny counts ($10k @ 1M units)
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1
19
34
14
11
1328
20
221721
36
30
37
10
24
1812 23
5
25
2915
166
897
2
35
34
13
26
33
31
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 100132 Heatsink, Aavid 60520 12 PCB 1
100104 Circuit board blank 1 100015 LED, Luxeon LXHL-LW6C 1
3 GATE 1 100110 Film Gate 1 100011 Backgate 1 100024 Film Spacer 1
4 Bottom 1 100144 Bottom Plate 1 100029 Leaf Spring 2
5 Knobreel 2 100106 Cover Bush 1 100151 Dowel .125 dia 2.000 long 1 100009 Driver 1 100153 Gripring .125 dia 1 100149 Knob bush 1 100007 Clutch, one-way, Torrington RC-02 1 100152 Washer, ss .125 id, McMaster 98019A310 1 100017 Knob, plastic McMaster 7354K15 1 100045 Felt washer 1
6 Reel 27 condentube 1
100031 Condenser lens, small Fisher Price 1 100105 Condenser Tube 1 100154 O-ring Buna -120 1 100035 Retaining ring, internal 1.062 dia 1 100031b Condenser lens, large, Fisher-Price 2
8 100162 Spacer, condenser lens, short 19 100136 Spacer, condenser lens, long 1
10 100163 Spacer, projector, short 111 FHMS Phillips M4x20 812 PHMS Phillips M4x8 613 PHMS Phillips M4x6 514 PHMS Phillips M5x16 815 FHMS Phillips M4x12 616 PHMS Phillips M4x12 117 PHMS M4x8 618 100150 Endplate, Right 119 100160 Endplate, Left 120 100100 Front Plate 121 100138 Projector Lens Housing 122 100148 End Spacer 223 100145 Top Plate 124 100158 Window Edmund R39-773 125 100146 Handle 126 100161 M5 Acorn Nut 127 100147 Half Bridge 128 100012 Focus Screw McMaster 92558A170 129 100143 Spacer, .25 dia, .19 long 430 100156 Spacer, projector, long 131 FHMS Phillips M4x8 232 100150 Washer, Nylon, MSC 05401757 133 100159 Detent 134 100101 Bumper, rubber McMaster 9540K35 835 100039 Switch, SPST rocker Carlingswitch 136 100155 Projector lens, concave 137 100157 Projector lens, plano 1
D
C
B
AA
B
C
D
12345678
8 7 6 5 4 3 2 1
APPLICATION
DIMENSIONS ARE IN MILLIMETERSTOLERANCES: 0,1MM ANGULAR: 0 30'
MATERIAL
FINISH
DRAWN
APPROVED
DATENAME
TITLE:
SIZE
BDWG. NO. REV
SCALE 2:5
UNLESS OTHERWISE SPECIFIED:
KINKAJOU DELTA100141
DO NOT SCALE DRAWING
REMOVE ALL BURRS AND SHARP EDGES
allen 21july04
Anatomy of a BOM• Plastic • Purchased Parts • Electrical Components • Consigned Components • Deco • Packaging • Assembly Labor • CM Profit, Overhead and Scrap • Overland Transportation
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• Does it matter that it is a gear???
• Components (3) 1.Material Cost = Part Weight * Resin Cost 2.Machine Overhead: = Hourly Cost * Cycle Time (sec) / (3,600 sec / hr) 3.Factory Mark-up, Scrap and Overhead (%)
• Total Part Cost: = (Material Cost + Overhead Cost) * (1+Factory M/U)
How to Calculate Plastic
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HK Resin Prices (USD/Ton)
Reference: http://www.nhh.com.hk/eng/trading/price_trend.asp (you will need to create a login)
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Item Cost (USD)
280 Ton / hr $15.48
220 Ton / hr $10.96
180 Ton / hr $8.38
140 Ton / hr $7.09
100 Ton / hr $5.80
80 Ton / hr $5.16
Example PRC
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How to Calculate EE Costs
• Cost = Component * Usage • Separate high cost components over a certain
threshold. Apply a lower mark-up. • Apply Factory M/U
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Typical PRC CM Margins (Profit, Scrap, Overhead)
PCBA 6–8%
Toys 12%
Consumer 15%
Medical >40%
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Other BOM Costs
• Deco (Tampo, Paint, etc.) • Labor (PRC $2 – 6 / hr) • Packaging (Gift + Master)
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Schedule
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Schedule
•Many consumer products are driven by the Christmas (which has a fixed date). Plan conJngency in your schedule. Things never go according to plan.
Have an onsite presence. Track schedule carefully and take correcJve acJons early. Avoid: “There is never Jme to do it right the first Jme, but there is always Jme to do it again. ”
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The Road to Production
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Detailed Milestones‣Hand Over / Kick-‐Off
Form CM Team Contact Lists / Roles and ResponsibiliJes
ME and EE File transfer Works Like / Looks Like Samples CM trip to the US if possible (access to models and team, relaJonship building).
Factory Input Components
Engineering Quality ProducJon Planning (interface with Sales)
Sourcing / MA / CosJng LogisJcs Process / Procedure Financial (modeling and payments)
Pre-‐ProducJon Milestones Tool Release
Tool Start (TS) First Shots (FS) Engineering Pilot 1 (EP1) EP2 EP3 Final Engineering Pilot (FEP) ProducJon Pilot (PP)
ProducJon ProducJon Start (PS) Ramp
Engineering Change NoJce (ECN) Sustaining (Quality Up / Cost Down) Sunset
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Quality
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Quality•DefiniJons:
•Quality = Customer SaJsfacJon = Performance – ExpectaJons •“Fitness for Use” Incoming Quality Control: Use good ingredients. Build and test along the way. Use sub-‐components. StaJsJcal Process Control (SPC) / Yield. Find out now, not later. Sample TesJng: Temp/Humidity; TransportaJon; Drop; T/T; Small Parts; Heavy Metals;
Compliance; FuncJonal; Life. How do tests match reality? ISTA-‐3A. Final InspecJon / Acceptable Quality Levels (AQL) Walk the line. Get your hands dirty. It is much easier (and less expensive) to make changes before ProducJon Start. What happens if something fails? Will make or break a product … and a Company! Quality is rarely considered in the engineering phase by startups due to schedule, cost and
technical pressures. Watch out for the Unknown Unknowns. Strong indicator of long term success, etc. Can you answer the quesAon “How do you know the product is good”?
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Recommended Reading
"Factory Girls", Leslie Chang: W.S.J. Reporter Who Lived In China Interviewing Migrant Factory Workers In The Pearl River Delta. Great Insight Into The Workforce.
"Poorly Made In China", Paul Midler: Light, Humorous,
"Mr. China", Tim Clissold: Older Humorous Memoir Of One Of The First Westerners