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Early Supplier Early Supplier
DevelopmentalDevelopmental InputInputCortec Precision Sheetmetal and Machining
March 2012
Innovative Solutions for Commodity Specific Manufacturing
IntroductionIntroduction• How valuable is supplier input when it comes to minimizing design cost, cost How valuable is supplier input when it comes to minimizing design cost, cost
effective materials and cost efficient processing for your new product? effective materials and cost efficient processing for your new product?
• Early Supplier Developmental Input (ESDI) is a 2Early Supplier Developmental Input (ESDI) is a 2ndnd set of eyes at the front end of set of eyes at the front end of the NPI process that can lead to major producibility and procurement the NPI process that can lead to major producibility and procurement advantages.advantages.
• Cortec has an ESDI Program that will provide critical risk assessment as it Cortec has an ESDI Program that will provide critical risk assessment as it pertains to the manufacturing of your new product. DFX; DFP, DFM & DFT pertains to the manufacturing of your new product. DFX; DFP, DFM & DFT observations on everything from Raw Material, Outside Services, Procured observations on everything from Raw Material, Outside Services, Procured Components, Logistics, Packaging and Shipping. Components, Logistics, Packaging and Shipping.
• Real-time consultation on the Quality Output of materials when processed Real-time consultation on the Quality Output of materials when processed through our manufacturing facility.through our manufacturing facility.
• By providing input on materials that work best with a specific child prototype or By providing input on materials that work best with a specific child prototype or electromechanical parent design, those contributions prevent potential problems electromechanical parent design, those contributions prevent potential problems during manufacturing. By identifying these issues in advance, you're more likely during manufacturing. By identifying these issues in advance, you're more likely to experience a smooth product realization process once your new product has to experience a smooth product realization process once your new product has been launched.been launched.
Cortec Precision Sheetmetal 2011
Early Developmental SolutionsEarly Developmental Solutions
When you send Cortec an RFQ it will be reviewed by our Estimating Team (ET).When you send Cortec an RFQ it will be reviewed by our Estimating Team (ET).
Our E.T. has Sheet Metal & Frame Manufacturing, Machine Shop, Our E.T. has Sheet Metal & Frame Manufacturing, Machine Shop, Mechanical/Engineering, Add Value Assembly, NPI Development and Product Mechanical/Engineering, Add Value Assembly, NPI Development and Product Transfer experience.Transfer experience.
They possess knowledge of material pricing and services related to your Build To They possess knowledge of material pricing and services related to your Build To Print fabrication and assembly needs.Print fabrication and assembly needs.
Our Drawing Process includes DFX feedback during conceptual design stage.Our Drawing Process includes DFX feedback during conceptual design stage.
We are proficient at expediting and providing real-time solutions.We are proficient at expediting and providing real-time solutions.
Actively propose Integrated solutions.Actively propose Integrated solutions.
Advise on potential processing inefficiencies.Advise on potential processing inefficiencies.
Make logical progression of design recommendations from NPI thru production life Make logical progression of design recommendations from NPI thru production life cycle and value-added assembly.cycle and value-added assembly.
Our Experts provide cost impact analysis when revision changes.Our Experts provide cost impact analysis when revision changes.
PFMECA reporting can be conducted.PFMECA reporting can be conducted.
Ensure lines of communication are open and maintained daily to interface with Ensure lines of communication are open and maintained daily to interface with corresponding personnel.corresponding personnel.
Capable of working on special projects from NPI to Production transition.Capable of working on special projects from NPI to Production transition.
Cortec Precision Sheetmetal 2011
ESDI DFP ReportingESDI DFP Reporting
Cortec Precision Sheetmetal 2011
Microsoft Excel Worksheet
DFP - Material Assessment & Material Budgetary Quote
sample
TYPE
BOM Item
Number
Metric MaterialDescription and Imperial
Equivalent
QTY Required
to build 2 Frames
Metric 1, 2, & 3 200 x 100 x 10MM WALL RECT TUBE 4
Imperial "8" x 4" x .375 WALL A500B STEEL,
RECT TUBE 4
Metric 4 150 x 100 x 8MM WALL RECT TUBE 4
Imperial "6" X 4" X .312 WALL A500B STEEL,
RECT TUBE 4
Metric 5 & 7 100 x 50 x 8MM WALL RECT TUBE 5
Imperial "4" X 2" X .312 WALL A500B STEEL,
RECT TUBE 5
Metric 8 32MM THK, PL STRUCTURAL STEEL 1
Imperial "2" X 1-1/4" THK STEEL RECT FLAT
BAR 1
Metric 102.5MM (MILD CARBON HRS STEEL
PLATE, A36) 1
Imperial "12 GA CRS (0.1046) ASTM A1008 CS
TYPE B 1
Metric 6
19MM THK PL, STRUCTURAL STEELSUPPLIER DOES NOT SUPPORT,
NEXT SIZE UP IS 20MM (.7874 THK) 1
Imperial ".750 THK PLT ASTM A36
48" x 96" 1
Metric 913MM THK, PL STRUCTURAL STEEL
32" X 60" 1
Imperial "
HOT ROLLED PICKLED & OIL .500 (PLATE A36)
32" x 48" 1Metric 11 COPPER SH, 1MM THK 1
Imperial ".040 THK, (1/4 HARD) OFE COPPER
C10100 HO1, ASTM B 152 1
Using a sheet metal cover as an Using a sheet metal cover as an example, Is it possible that the example, Is it possible that the fasteners you are using could fasteners you are using could be substituted for a less be substituted for a less expensive product or be expensive product or be integrated in our factory at the integrated in our factory at the next level of assembly? next level of assembly?
Cost savings pass through to Cost savings pass through to you when suggesting alternative you when suggesting alternative materials or processing ideas materials or processing ideas that work as effectively but cost that work as effectively but cost much less because they are much less because they are incorporated into your design incorporated into your design from the very start. from the very start.
ESDI DFM ReportingESDI DFM Reporting
Cortec Precision Sheetmetal 2011
ESDI: 1. Instead of using CLS-832-1 Cortec suggested using SP-832-1.
Why? Pem product technology has advanced and supplier created a new type of hardware designed specifically for installment into Stainless Steel base material. This new Pem product eliminates the need to tack weld the old type of hardware customarily used resulting in cost savings. 15% per part cost savings include elimination of tack weld, grinding and additional regraining of exterior surfaces to remove weld discoloration in the manufacturing Sequence of Events (SOE).
• Quality of new product is directly related Quality of new product is directly related to how involved your ESDI partner is at to how involved your ESDI partner is at the beginning of the NPI process. When the beginning of the NPI process. When consulting Cortec during the development consulting Cortec during the development stage, expect to have a product designed stage, expect to have a product designed with the right materials that conform to with the right materials that conform to drawing specifications.drawing specifications.
• When products are designed When products are designed withoutwithout the the contribution of an ESDI partner, there's a contribution of an ESDI partner, there's a possibility requested materials will not possibility requested materials will not work well with the final product. Materials work well with the final product. Materials used in the production of your new used in the production of your new product could be inconsistent, laborious product could be inconsistent, laborious and very expensive to incorporate or and very expensive to incorporate or rework. rework.
• Cortecs’ ESDI solution is to provide an Cortecs’ ESDI solution is to provide an onsite resource and be an adjunct onsite resource and be an adjunct member of your Engineering team.member of your Engineering team.
ESDI: Quality Review ESDI: Quality Review
Cortec Precision Sheetmetal 2011
Flat Head Screws• Flat Head Screws
supposed to be removed.• Cause: Frame
manufacturer failed to remove Flat Head Screws before painting.
• Type of failure – Minor, weld department did not follow customer approved OMS.
• Action: Option to Return to supplier or PAINT frame.
Cortec Precision Sheetmetal Confidential
Slide - 1
Metal Filler Missing• Workmanship
• Failure to Follow OMS
• Type of failure – major
• Action: Rework by stripping paint from seam and repeat OMS #12 STEPS 1-15
Cortec Precision Sheetmetal Confidential
Slide - 1
ESDI Solutions identified during RFQ ProcessESDI Solutions identified during RFQ Process
& change control& change control
Cortec Precision Sheetmetal 2011
Cortec Precision Sheetmetal Confidential
Slide - 1
RFQ
• Estimators Review RFQ Package
• Prepare Pre-FMEA statement• Create Redline drawing to WI 7.1.3• Adds Comment to Quote Comment Field.
• Estimators send Quote Letter to Customer along with Pre-FMEA statement and Redline drawing file.• Adds Popup Note in History Tab and clicks Popup Notify Note
• Customer places order.• Customer Service sees Popup notification and triggers SPS Process.
• Customer places order.• Customer Service sees Popup notification and triggers SPS Process.
• ME confirms need for SPS and SPS details.
• ME always attaches revised redline to FabriTRAK.• Must attach to BOTH Quote and Router.
• ME confirms redline created by Estimator.
• ME Reviews drawing files for any other omissions that will prevent product realization during WIP.
• ME gathers data and updates the redline drawing file if required.
• ME files SPS / PR / (other customer acronym).• Adds comments to FabriTRAK quote comment field.
• ME updates router and adds comments to transaction log.
• ME updates router and adds comments to transaction log.
• ME notifies ALL departments affected by SPS submittal.• Estimators• Customer Service•FAI Team
• ME saves a copy of the solution in the Q:/Drive Part number folder.• Adds comments in Quote and Router, attaches solution to FabriTRAK.
RFQ Processing and Identification of ESDI Opportunities, DXF reporting and design challenges
Applying our ESDI approach affords the opportunity to reassure optimal Applying our ESDI approach affords the opportunity to reassure optimal “design implementation” for manufacturability and other processing risks in a “design implementation” for manufacturability and other processing risks in a timely manner, enabling Research and Development the opportunity to timely manner, enabling Research and Development the opportunity to respond with minimal impact to your product release schedule. respond with minimal impact to your product release schedule.
This fully-integrated and efficient approach assures that your company This fully-integrated and efficient approach assures that your company reduces costs because it allows earlier identification of processing issues, reduces costs because it allows earlier identification of processing issues, and it applies your set tolerance for risk in a consistent manner. and it applies your set tolerance for risk in a consistent manner.
Enables real-time responsiveness and effective direct design input.Enables real-time responsiveness and effective direct design input.
Allows significant processing alternatives to control risk, cut cost and improve Allows significant processing alternatives to control risk, cut cost and improve quality. quality.
Provides consistent risk analysis, assessment and reporting.Provides consistent risk analysis, assessment and reporting.
Conduct risk control validation .Conduct risk control validation .
Cortec guarantees a fully- integrated and value-added approach towards Cortec guarantees a fully- integrated and value-added approach towards assessing and improving your design implementation. assessing and improving your design implementation.
Early Developmental Input BenefitEarly Developmental Input Benefit
Cortec Precision Sheetmetal 2011
ESDI Benefit: Quantitative ResultsESDI Benefit: Quantitative Results
Cortec Precision Sheetmetal 2011
12ncDescription2010
Cosmetic Class A Finish,
2 sidesQ3 2011
Cosmetic time savingsClass A Finish Outside SurfaceClass C Finish Inside Surface Quantitative savings 12-02-2011 TQS
xxxx.000.88882 RS XTIV LO-FRONT PANEL IL LSY244.31$ 35.12$ Time savings 1 minute per part
1.08$ 34.04$
xxxx.000.88882 RS XT4 INN.COV. LSY2 RH ASSY289.78$ 272.33$
Multiple piece assembly, Time savings 5 min per side; 10 min.
total 10.83$ 261.50$
xxxx.000.88882 RS XT4 INN.COV. LSY2 ILL ASSY258.23$ 250.17$
Multiple piece assembly,Time savings 5 min per side; 10 min.
total 10.83$ 239.34$
xxxx.000.88882 RS XT4 INN.COV.LSY1/2 MID ASSY221.93$ 210.84$
Multiple piece assembly,Time savings 5 min per side; 10 min.
total 10.83$ 200.01$
xxxx.000.88882 RS XT4 INN.COV. LSY1 RH ASSY283.17$ 271.86$
Multiple piece assembly,Time savings 5 min per side; 10 min.
total 10.83$ 261.03$
xxxx.000.88882 RS XT4 INN.COV. LSY1 ILL ASSY294.37$ 279.65$
Multiple piece assembly,Time savings 5 min per side; 10 min.
total 10.83$ 268.82$
xxxx.000.88882 RS AIR SHOWER COVER PLATE ASSY453.42$ 417.18$ Time savings 10 min. per side;
20 min. total 21.66$ 395.52$ xxxx.000.88882 RS XT4 TOP COVER ILL LSY2 ASSY551.00$ 526.21$ Time savings is 10 min. 10.83$ 515.38$ xxxx.000.88882 RS XT4 TOP COVER MID LSY2 ASSY553.91$ 526.23$ Time savings is 10 min. 10.83$ 515.40$ xxxx.000.88882 RS XT4 TOP COVER RH LSY2 ASSY596.50$ 570.84$ Time savings is 10 min. 10.83$ 560.01$ xxxx.000.88882 RS XT4 TOP COVER ILL LSY1 ASSY554.97$ 527.25$ Time savings is 10 min. 10.83$ 516.42$ xxxx.000.88882 RS XT4 TOP COVER MID LSY1 ASSY440.00$ 420.26$ Time savings is 10 min. 10.83$ 409.43$ xxxx.000.88882 RS XT4 TOP COVER RH LSY1 ASSY535.75$ 508.98$ Time savings is 10 min. 10.83$ 498.15$ xxxx.000.88882 RS XT4 FRONT COVER LSY1 ASSY421.96$ 400.86$ Time savings is 20 min. 21.66$ 379.20$ xxxx.000.88882 RS XT4 UP-FRT COVER IL-Y2 ASSY326.97$ 311.29$ Time savings is 7 min. 7.58$ 303.71$ xxxx.000.88882 RS XT4 FRONT COVER RH-Y2 ASSY424.90$ 390.04$ Time savings is 5 min. 5.42$ 384.62$ xxxx.000.88882 RS XT4 FRONT COVER MID-Y2 ASSY446.11$ 384.73$ Time savings is 5 min. 5.42$ 379.31$ xxxx.000.88882 RS LOS RH COVER ASSY580.46$ 554.52$ Time savings is 20 min. 21.66$ 532.86$ xxxx.000.88882 RS XT4 COVER MOUNT STRIP SA-A71.37$ 62.10$ Machined flat barxxxx.000.88882 RS XT4 COVER MOUNT STRIP SA-B69.07$ 60.39$ Machined flat bar
7,418.18$ 6,980.85$ Total 6,654.75$ Percentage Quantitative Savings -24.67%
Early Developmental Input
New Product DesignIssues & Issues &
OpportunitiesOpportunities
IdentifiedIdentified
Material Processing Issue
Mechanical Fit Issue
Early Supplier Early Supplier
Developmental InputDevelopmental Input
Cost Overruns
Cortec Precision Sheetmetal 2011
New Product Design
Logical Manufacturing Progression
Cortec Precision Sheetmetal 2011
New New Product Product DesignDesign
Drawing Review
POR/PFMECA/ESDI/DFX
Sheetmetal Processing
Machine Shop
Processing
Welding Shop
Processing
SSilk ilk SScreen creen PProcessingrocessing
Value-Add
Assembly
Class 10,000
Cleanroom
Value-Add
Assembly
Class 1000
Cleanroom
Process Control Validation (PCV)
SPC/FAI
Shipping
Project Lessons
Learned
Paint Shop
Processing
PCVPCV PCV
PCV PCV PCV
PCV
PCVPCV PCV PCV
Manufacturing Enhancements
Cortec Precision Sheetmetal 2011
78,000 Sq Ft Manufacturing Facility78,000 Sq Ft Manufacturing FacilitySheetmetalSheetmetal
Light out laser capabilities addedLight out laser capabilities added
QTY 9, AMADA Press brakes, multiple LASER and Punch PressesQTY 9, AMADA Press brakes, multiple LASER and Punch Presses
Machine ShopMachine Shop
Qty 7, 3-AXIS Vertical Mills, Qty 7, 3-AXIS Vertical Mills,
Qty 1 (Lathe) CNC turning CenterQty 1 (Lathe) CNC turning Center
• 14 weld stations – some dedicated work stations to support 4LPM & 2LPM 14 weld stations – some dedicated work stations to support 4LPM & 2LPM projects addedprojects added
• Both Powder and Wet coat paint booths can support up to 16ft tall frames,Both Powder and Wet coat paint booths can support up to 16ft tall frames,
• Material KAN-BAN inventory Material KAN-BAN inventory
• Onsite rework team for real time change controlOnsite rework team for real time change control
• 90 day strategic plan in 90 day strategic plan in progressprogress for a fully functional ISO 7 CL 10,000 for a fully functional ISO 7 CL 10,000 Value-Add Cleanroom.Value-Add Cleanroom.
Enhanced Machine Shop Capabilities
Cortec Precision Sheetmetal 2011
More MachinesMore Machines
Better Process ControlsBetter Process Controls
More CapacityMore Capacity
Project Success Criteria
Cortec Precision Sheetmetal 2011
Multiple Frames developed in Parallel with Optimum Success Criteria
Ramp to meet customer demand in less than 30 days.
Dedicated work stations through entire process to support both projects
PFMECA conducted and reported.
Added dedicated project weld stations.
Daily CFT and project timeline updates.
JIT raw material and procured materials inventory.
Tab and Key tubing design and fixturing for better welding controls.
Incorporated Value-Add materials in ISO 8 cleanroom during production.
Process Control Validation and OMS documented.
Multiple ESDI and customer design changes cut-in before and during development.
Onsite rework and ESDI participation with customer Engineering team eliminated costly logistics burden.
Imperial material solution provided during production when European metric material supplier failed to deliver attributed to ESDI, CFT’s and PR reporting.
100% Product Yield
Participated in crate recycling program to reduce logistics burden.
Lessons Learned and reported.
Project Success Criteria
Cortec Precision Sheetmetal 2011
Multiple Frames developed in Parallel with Optimum Success Criteria
Ramp to meet customer demand in less than 30 days.
Dedicated work stations through entire process to support both projects
PFMECA conducted and reported.
Added dedicated project weld stations.
Daily CFT and project timeline updates.
JIT raw material and procured materials inventory.
Tab and Key tubing design and fixturing for better welding controls.
Incorporated Value-Add materials in ISO 8 cleanroom during production.
Process Control Validation and OMS documented.
Multiple ESDI and customer design changes cut-in before and during development.
Onsite rework and ESDI participation with customer Engineering team eliminated costly logistics burden.
Imperial material solution provided during production when European metric material supplier failed to deliver attributed to ESDI, CFT’s and PR reporting.
100% Product Yield
Participated in crate recycling program to reduce logistics burden.
Lessons Learned and reported.
Product Transfer Services to LCR
Cortec Precision Sheetmetal 2011
l • S. Korea
• Singapore
• Malaysia
• Europe
• China
• Canada
• Mexicali, Mexico
Value Add Assembly & CleanroomIs the Next Logical Step In Manufacturing
Cortec Precision Sheetmetal 2011
Com
ing
soon
!!!
Summary
Cortec Precision Sheetmetal 2011
Cortec considers your company a valued partner and would like the opportunity to review your design and provide
The proposed ESDI solution is for an assigned project or Technical P.M. to work as an adjunct member of your Engineering team, Quality team, Supply Base Management or other groups as required.
Machine Shop capacity has increased with better controls and could be a stronger strategic resource to an existing partnership.
Welding and Large Frame Capacity has increased with better controls.
Multiple Frame projects with value-added assembly with 100% yield SPC, FAI process validation, and OMS documented and reported; benefits all Cortec customer base.
Strategic plan in progress to provide a Class 10,000 cleanroom for increased Value-Added assembly service in 90 days.
Streamlined communication to correct personnel at Cortec for better responsiveness.
Product Transfer Services to Low cost Region