Production Preparation Process

The SMS Technologies Quality Management System includes: ISO 9001, AS9100, ISO 13485, and

ISO/TS 16949They All Include Product Realization

Advanced Product Quality Planning Production Preparation Process Production Part Approval process

APQP, Flow Charting, Process FMEA, Control

Plan, 3-P & PPAP

APQP, Flow Charting, Process FMEA, Control

Plan, 3-P & PPAP APQP = Advanced Product Quality Planning

Build 1st-time Quality into the Production Process

FMEA = Failure Mode Effects Analysis Minimize Risk (DFM, DFT & Mistake-Proofing)

3-P = Production Preparation Process Build to Customer Demand Beginning at Launch

PPAP = Production Part Approval Process

PRODUCT QUALITY PLANNING TIMING CHART

CONCEPTINITIATION/APPROVAL

PROGRAM APPROVAL

PROTOTYPE PILOT LAUNCH

PLANNING

PRODUCTION

Production INPUTS|

Production OUTPUTS

Planning INPUTS

|Planning OUTPUTS

Product Design &Dev. INPUTS

|Product Design &

Dev. OUTPUTS

Process Design &Dev. INPUTS

|Process Design &

Dev. OUTPUTS

Product & ProcessValidation INPUTS

|Product & Process

Validation OUTPUTS

PLANNING

PRODUCT DESIGN AND DEV.

PROCESS DESIGN AND DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

SEI Process Flow DiagramProcess

Flow ChartProcess

Flow Chart

Input orOutputBlocks

InstructionalBlocks

DecisionBlocks

Start

SubroutineBlocks

(i.e. Rework)

Input orOutputBlocks

End

No

Yes

Process Failure Mode Effects Analysis

Proto-type, Pre-launch & Production Control Plans

Operator Work InstructionsWork Instructions with applicable drawings, etc. are developed for each material transformation:

Process Flow Chart

FMEAs

Control Plans

Operator Instructions

PPAP

Core Tools Applications

The Key Linkages for Customer Special Characteristics

Defining & Balancing The Cell

Transport1 day

ShippingStaging

500 units/wk100 units per

day50 units per

shift

SEI

Insp UltraCap assy

.5 min

Solder 2standoffs and 3resistors to flex

1.5 min

Solder 3 ultracaps to flex

cable7.5min

RTV Flex Cableto Cover2.2 min

Insp.5 min

Depanel 25up PCBA

.3 min

Insp.5 min

Hand solderCable

2.5 min

CCA-25000-1101

Insp.5 min

Assemble5.0 min

X-ray BGA &QFN

Depanel 4 uparray.3 min

Hand SolderJ4, J7

2.0 minCCA-25000-1301

Combo RF/GPS test4.3 min

Scan GPS andTXC SNs into

data base1.0 min

GPS/RFPCBAs in

chassis insp1.0 min

Final Insp4.3 min

Program andfunc test8.16 min

Solder ReedSwitch2.0 min

Install shieldcovers3.0 min

RTV 2nd

Cable5 min

Install slideswitch

1.75 min

Reed Switchinsp

.5 min(sample)

Install RotorySwitch

1.25 min

RTV 1stCable

5.0 min

Install Battcontacts3.0 min

Epoxy Antreed switch

2.75 min

Install Rotoryswitch knob

1.25 min

RTV ReedSwitch

1.75 min

Install RemoteAdaptor Assy

5.0 min

Install Antmatching

PCBA1.2 min

Chassis Insp1.0 min

Solder ant pinto PCBA

.5 min

Reed switchTest

.5 min

FIFO??

FIFO??

FIFO42

InstallMatching

Cable-RF Bd.5 min

Interim insp1.0 min

GPS Chassistest

6.0 min

VSWR Test3.0 min

Top CoverAssy

4.0 min

Battery Coverinstall

1.0

Interim Insp1.0 min

Install BladeAntenna.5 min

Full FuncTest

2.0 min

Final Inspand Docs5.0 min

Leak test2.0 min

Solder 5wires7.min

Pack out.33 min

Seal Screw.5 min

Instal RF Bd6

.0 min

InstallRadomeCover

6.0

Epoxymagnet to

Slide switch1.0 min

FIFO42

Final InspRF Func test

5.5 minX-ray BGA &

QFN

Depanel 4 uparay

.3 minApply Epoxy

FIFO42

CCA-25000-1201

Insp Contacts.5 min

Prep Pos Batterminal1.0 min

Prep Neg BatTerminal1.0 min

Trimfixture

forNegTerm

FIFO??

Calculating Takt TimeTotal Shift Hours = 8 X 60 min. X 60 sec. = 28,800 seconds-2 - 15-minute breaks X 30 min. X 60 sec. = 1,800 seconds-Start-up & Shut-down = 15 min. X 60 sec. = 900 seconds

Available Work Time = 26,100 seconds

Takt Time = Available Work Time / Customer Demand (units)

TAKT TIME = 26,100 Seconds / 50 Units = 522 Seconds

TAKT TIME = 522 Seconds / 60 = 8.7 Minutes

Build a cell that will produce one unit every 8.7 minutes!

Defining & Balancing The Cell

Transport1 day

ShippingStaging

500 units/wk100 units per

day50 units per

shift

SEI

Insp UltraCap assy

.5 min

Solder 2standoffs and 3resistors to flex

1.5 min

Solder 3 ultracaps to flex

cable7.5min

RTV Flex Cableto Cover2.2 min

Insp.5 min

Depanel 4 uparray.3 min

Hand SolderJ4, J7

2.0 min

Combo RF/GPS test4.3 min

Scan GPS andTXC SNs into

data base1.0 min

GPS/RFPCBAs andchassis insp

1.0 min

Final Insp4.3 min

Func test4.4 min

Solder ReedSwitch2.0 min

Install shieldcovers2.0 min

Install Battcontacts3.0 min

Epoxy Antreed switch

2.75 min

Install RemoteAdaptor Assy

3.0 min

Install Antmatching

PCBA1.2 min

Chassis Insp1.0 min

Solder ant pinto PCBA.5 min

FIFO4

InstallMatching

Cable-RF Bd.5 min

Interim insp1.0 min

GPS Chassistest

4.0 min

VSWR Test3.0 min

Top CoverAssy

4.0 min

Battery Coverinstall

1.0

Interim Insp1.0 min

Install BladeAntenna.5 min

Full FuncTest

2.0 min

Final Inspand Docs5.0 min

Leak test2.0 min

Solder 5wires7.min

Pack out.33 min

Seal Screw.5 min

InstallRadomeCover

6.0

Final Insp.5 min

RF Func test5.5 min

X-ray BGA &QFN

Depanel 4 uparay

.3 min

Apply Epoxy1.0 min

FIFO4

CCA-25000-1301RF

FIFO14

Insp Contacts.5 min

Prep Pos Batterminal1.0 min

Prep Neg BatTerminal1.0 min

Trimfixture

Depanel 25up PCBA

.3 min

InspP/O Chassis

insp

Hand solderCable

2.5 min

CCA-25000-1101

Pizzacutter

Pizzaand

Dremmeltool

Pizzacutter

Install RF BdPart 1

4.0

Instal RF BdPart 2

2.0 min

CCA-25000-1201GPS

Insp.5 min

AssembleRemote Conn

Adaptor5.0 min

Install slideswitch

1.75 min

Reed Switchalignmentand insp.5 min

Install RotorySwitch

1.25 min

Install Rotoryswitch knob

1.25 min

RTV ReedSwitch

1.75 min

Reed switchTest

.5 min

FIFO14

Epoxymagnet to

Slide switch1.0 min

FIFO4

Trimfixture

R/I to do

RTV 2nd

Cable5 min

RTV 1stCable

5.0 min

Final op pack outTop cover and Final assy

Ultra Cap sub assy

Blade Ant VSWR and final testGPS Test/RF InstallRotory/GPS Wiring

Bd insp - GPS/Radomeinstall

Remote Conn assy/insp/cover installRF Bd test/final assy

Insp/Combo testGPS Bd test/final assy

Ant matching/Remote adp assyBatt terminal Prep and assyInitial Chassis assyRTV Cables

Defining & Balancing The Cell

10

9

8

7

6

5

4

3

2

1

Operation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Min. 7.50 9.00 8.25 7.50 8.50 7.30 7.70 8.60 9.00 8.00 8.00 8.00 9.00 9.00 7.83

Until learning curves been achieved, work portions are allowed to vary slightly around the takt time until conducting further studies:

Preliminary SEI Cell Floor Layout

4 f

tF

ina

l T

ES

T a

nd

pa

ck

ou

t

7.8

8 m

in

4 ftRemote Conn

assy/insp/coverinstall

4 ftRotory/GPS

Wiring

10 ftRF Bd test/final assy

4 ftInitial Chassis

assy

4 ftGPS Test/RF

Install

4 ftBatt terminal Prep

and assy

3 ftRTV Cables

4 ftBd insp - GPS/Radome install

4 ftAnt matching/

Remote adp assy

10 ftGPS Bd test/final assy

6 ftInsp/Combo test

5 ftBlade Ant VSWR and

battery cover

3ft

To

p c

ove

r,L

ea

k te

st a

nd

Fin

al a

ssy

5 f

tU

ltra

Ca

p s

ub

ass

y

1201

1301

CH

AS

SIS

To

Shi

ppin

gM

AIN

CO

VE

R

1101

T TT

6 ftDebug Station

TFLOW

TT

S

Arb

or

T TEST

TD TORQUE DRIVER

S SOLDERING STATION

M MANTIS

O OVEN

De-

pane

l

S MMS

TDTD

TD TD

Hep

co

TD MS TD S M T

OOO

TD

S

TD

Varying The Cell Volume

Scaling Volume by Adding Shifts

# of Shifts Daily # Weekly # Monthly #1 50 250 10002 100 500 20003 150 750 3000

SEI Future State MapProd. Ctrl.

Wash

SMT Placement

& X-ray

Boards & Components

LT ~ 15.4 hrs.

VA =81 m in.

SEI

2525

2525

2525

Forecast = ~500 / week or ~50 / day / Shift

Takt = ~1 unit every 8.7 minutes

Pitch = 10 units

10

10

10

360 min.

48 min.

Beacon Final Assembly,Test & Pack-out

Daily

Shipping

Install & SolderAntenna &

Adaptor Assembly

Solder & Inspect Ultra-cap Assembly

RTV Flex Cable

max. 14

pcs.

FIFOFIFO

max. 4

pcs.

FIFOFIFO

RF Functional Test & EpoxyApplication

Install BatteryContact & Epoxy

Antenna Reed Sw.

Install Slide Switch,

Install Reed Switch &

RTV 1st Cable& 2nd Cable

max. 14

pcs.

FIFOFIFO

max. 14

pcs.

FIFOFIFO

max. 42

pcs.

FIFOFIFO

Reed SwitchRTV Application

max. 42

pcs.

FIFOFIFO

Epoxy Magnet& Slide Switch

AssembleRemote Adaptor

Assembly

Inspect & InstallTop CoverAssembly

GPS Board 2nd Assembly,

Inspection & Test(Pacemaker)

Hand SolderAntenna Cable

Assembly

360 min. 120 min.

1 min. 8 min.6 min.18 min.

01

02

318

112

18 648

1604

11

16

18

125

SEI Future State Map 2Prod. Ctrl.

Wash

SMT Placement

& X-ray

Boards & Components

LT ~ 4 hrs.

VA =80 m in.

SEI

2525

2525

2525

Forecast = ~500 / week or ~50 / day / Shift

Takt = ~1 unit every 8.7 minutes

Pitch = 10 units

10

10

10

35 min.

48 min.

Beacon Final Assembly,

Test & Pack-out

Daily

Shipping

Install & SolderAntenna &

Adaptor Assembly

Solder & Inspect Ultra-cap Assembly

RTV Flex Cable

max. 14

pcs.

FIFOFIFO

max. 4

pcs.

FIFOFIFO

RF Functional Test & EpoxyApplication

Install Slide Switch, Reed Switch

& Battery Contact & Apply Epoxy to

Antenna Reed Switch

max. 14

pcs.

FIFOFIFO

maximum 4 pieces

FIFO

1st & 2nd Cable & Reed Switch

RTV Application

max. 4

pcs.

FIFOFIFO

Epoxy Magnet& Slide Switch

AssembleRemote Adaptor

Assembly

Inspect & InstallTop CoverAssembly

GPS Board 2nd Assembly,

Inspection & Test(Pacemaker)

Hand SolderAntenna Cable

Assembly

122 min.

10 min. 8 min.14 min.

01

110

214

112

18

5481604

01

18

325