Manufacturing Transformation

TE Connectivity

VP – Technology: Advanced Manufacturing

Dr. Roberto Lu

September, 2013

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Ship Building, Norway, Viking Age (800 AD – 1050 AD)

Building a Viking ship or a boat of Norse design involves a traditional craftsmanship which is a refined art, delivered from master to apprentice, usually from father to son for generations. The skills were passed on as tacit knowledge, mostly orally and by doing, usually without any detailed drawings or accurate diagrams. In addition, very often the crafter was himself an experienced seafarer, having participated in seasonal fisheries in the fjords and offshore from his early teens, giving him a first hand experience of what distinguished a good boat from a dangerous one.

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Industrial Revolution, Britain, 18th Century

Major technological developments The commencement of the Industrial Revolution is closely linked to a small number of innovations, beginning in the second half of the 18th century. By the 1830s the following gains had been made in important technologies:

Textiles

Steam

Iron making

Iron and Coal Steam Engine

Iron Bridge

Spinning

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Ford Model T, United States, 20th Century

The Ford Model T revolutionized the way we murder our planet, and is the greatest invention known to man, certainly an improvement on the wheel anyway.

On this day in 1913, Henry Ford installs the first moving assembly line for the mass production of an entire automobile. His innovation reduced the time it took to build a car from more than 12 hours to two hours and 30 minutes.

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Airbus, France, 20th Century

1967 - 2013 Airbus SAS is an aircraft manufacturing subsidiary of EADS, a European aerospace company. Based in Blagnac, France, a suburb of Toulouse, and with significant activity across Europe, the company produces approximately half of the world's jet airliners.

The company produces and markets the first commercially viable fly-by-wire airliner, the Airbus A320, and the world's largest passenger airliner, the A380.

How is

A380

made?

Design

Production

Transport

Final Testing

Delivery

Assembly

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All the pictures are from Airbus company site

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BMW Flexible Manufacturing, Germany, 21st Century

BMW believes the future belongs to flexible manufacturing. The German manufacturer has a long history of building cars to customer order. In 2008, 70 percent of its production was built to customer order. “We anticipate in the future that customers will want more individuality and more customer order flexibility,” said Rich Morris, Vice President, assembly, BMW. [7]

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TE Connectivity

TE Connectivity (NYSE: TEL) is a technology leader in the world’s fastest growing markets, helping connect power, data and signal in everything from automotive and aerospace to broadband communications, consumer, energy and industrial applications. By helping our customers meet the need for greater energy efficiency, ever-increasing productivity and faster, more reliable data, TE’s market-defining technologies and engineering expertise is setting the pace for the future of connectivity.

All the pictures are from TE Connectivity company site

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Production Tendency (today)

Manual Production Line

Automatic Production Line

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Do not Reproduce or Distribute

Automation Technology Evolution

• Product Specific Tooling

• Example: one product type assembly line

• Modular Design and Less Tooling

• Example: Flexible Stitching

• Support 10 product types

• 20 minutes change over

• Programmable Assembly With Flexible Tooling

• Example: Programmable Line

• Support 30+ product types

• 10 minutes change over

• Example: Fixture Switchable

• Support 5 families types of 80+ products

• 10 minutes – 2 hours change over

• Dual Arm Humanlike Robot Assembly

• No hard tooling

2012 2013 2014 2015 Year

To

olin

g R

ed

uctio

n a

nd

Fle

xib

ility

In

cre

ase

• Highly Flexible

• One “Push-Button”

Change Over

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Enabling Technologies

2012 2013 2014 2015 Year

Bowl Feeder

Flex Feeder with Vision Guidance

Robotic Pick and Place Dual Arm Humanlike Robot

Soldering Gun Laser Soldering Precise Tin Feeding

CAM Driven Nano Actuator Servo Driven

CCD Camera Smart Camera 3D Camera Sensor Fusion

Feeding Technology

Vision Technology

Driving Technology

Joining Technology

Resistance Welding Laser Welding

Enablin

g T

echnolo

gy

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Transformational Manufacturing in Pipeline

2012 2013 2014 2015 Year

Ma

ss C

usto

miz

ed

Au

tom

atio

n P

latf

orm

• Highly Flexible

• One “Push-Button”

Change Over

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References

1. http://www.bbc.co.uk/history/0/20979973 2. http://www.historyworld.net/wrldhis/plaintexthistories.asp?historyid=aa37 3. http://www.britainexpress.com/History/18th-century-Industrial-Revolution.htm 4. http://en.wikipedia.org/wiki/Industrial_Revolution 5. http://en.wikipedia.org/wiki/Airbus 6. http://www.airbus.com/company/history/the-narrative/ 7. http://www.manufacturingdigital.com/sectors/bmw-chooses-flexibility-over-lean-manufacturing 8. http://www.norway-hei.com/norwegian-boat-building.html 9. http://www.nmi2008.com/2009/02/19/norway%E2%80%99s-shipbuilding-industry/ 10. http://home.online.no/~joeolavl/viking/baatbyggerier.htm 11. http://en.wikipedia.org/wiki/Viking_ships 12. http://www.shipbuildingnorway.com/volume-17/ships-delivered-in-2012-2/ 13. http://uncyclopedia.wikia.com/wiki/Ford_Model_T 14. http://en.wikipedia.org/wiki/Ford_Model_T 15. http://www.history.com/this-day-in-history/fords-assembly-line-starts-rolling 16. http://www.ford.co.uk/experience-ford/Heritage/EvolutionOfMassProduction 17. http://www.econedlink.org/lessons/index.php?lid=668&type=student 18. http://www.carscoops.com/2007/07/bmws-innovative-flexible-manufacturing.html 19. http://content.time.com/time/magazine/article/0,9171,1640398,00.html 20. http://www.chinadaily.com.cn/cndy/2012-05/24/content_15372549.htm 21. http://optics.org/article/35338/mini 22. http://wardsauto.com/news-amp-analysis/bmw-cranking-flexibility-sequence-deliveri 23. https://www.press.bmwgroup.com/pressclub/p/pcgl/pressDetail.html?title=bmw-i-innovation-days-

2013&outputChannelId=6&id=T0139951EN&left_menu_item=node__6729es-spartanburg 24. http://www.hangthebankers.com/islave-foxconn-workers-strike-over-iphone-5-demands/ 25. http://image.baidu.com/i?tn=baiduimage&ct=201326592&lm=-

1&cl=2&nc=1&word=%E5%AF%8C%E5%A3%AB%E5%BA%B7%E7%94%9F%E4%BA%A7%E7%BA%BF&ie=utf-8 26. http://www.festo.com/cms/en-us_us/15915.htm 27. http://www.systemdevices.co.uk/portfolio/epson-robotic-arms-2/ 28. http://www.generalscan.com/en-us/Solutions/ElectronicsApplications.aspx

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June 04, 2013

TE Manufacturing Advantage

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