Reducing Scrap and Rework
John BuchowskiDirector, MCAD Product Management
PTC
© 2006 PTC2 Forward Looking Information Subject to Change without Notice
Scrap and Rework….
Can the application of PLM technologies lead to reductions in scrap and rework in product development?
Agenda of presentation
Causes of scrap/rework
– Which of these causes can be addressed with PLM technologies
Customer challenges/problems
Technology Solutions
© 2006 PTC3 Forward Looking Information Subject to Change without Notice
Scrap and Rework….
What are some of the core causes of scrap and rework?
Wrong designs manufactured
– Duplicate parts
– Incorrect versions
Parts/components as manufactured do not meet quality standards
– Injection Molded components with sink marks? Short shots?
– Poor tolerances, components cannot be assembled….
Designs that fail to satisfy requirements
– Aesthetic
– Functional
– Ergonomic All of these can be significantly impacted by
implementing PLM technologies and processes
© 2006 PTC4 Forward Looking Information Subject to Change without Notice
Typical “As-Is” Design Communication and Data Sharing
LocalCAD Vault
ManufacturingManufacturing
OtherEngineers
CAD Vault
MarketingMarketing
OvernightDelivery
ERP
DesignPartnerDesignPartner
CustomersCustomers
CAD
CAD
Engineer
Fly to remotelocation
Convert data for non-technical audience
Courier
Create new Inventory Item
Manage Change
reuse designs
Locate Existing Designs
Share and Review Design
Iterations
Manage Manufacturing
Feedback
Constantly Assess Change impact
Deal with Sourcing Requirements
Access Field for Input
Meet Market Requirements
SuppliersSuppliers
DistributedManufacturing
DistributedManufacturing
CAD
ProcurementProcurement
ServiceService
SalesSales
Prototypes
OvernightDelivery
The Big Culprits: Network Folders, FTP, Ad Hoc Email / Paper Processes
© 2006 PTC5 Forward Looking Information Subject to Change without Notice
Are There Opportunities For Improvement?
RoHS
APQP
21 CFR Part 11How do you insure remote sites, suppliers and customers are working from the correct versions of information?
What is the significance of achieving and maintaining regulatory compliance?
How quickly can you respond when sales changes customer requirements (ECNs, ECOs)?
How much time do your teams spend searching for information? How do you ensure it’s the right version? How do you promote reuse?
How is Bill of Material (BOM) information exchanged between Design and Production?
© 2006 PTC6 Forward Looking Information Subject to Change without Notice
PLM As The Backbone For Improvement
1. Centralized Data Vault Revision / Lifecycle Control xCAD (parts, assys, etc) Document Management Visualization Access with Web browser
2. Change Management Change Visibility / Notification Documents, Drawings, BOM Problem Reports, ECRs, ECNs Metrics and Audit Trail
3. Collaboration / Sharing Virtual Design Teams External Partners (Design & Mfg) New Product Introduction Quality & Compliance
4. Integration with MRP / ERP Change Activity Approved Vendors / Manufacturers Common BOM Driving Operations
Company-wide
© 2006 PTC7 Forward Looking Information Subject to Change without Notice
Design Control/Design Communication
No company is too small, or product too simple to leverage for effective product data management
Problem…
What version of a design has been delivered to manufacturing?
Are there pre-existing components we can choose from?
Are these parts from an approved supplier?
Have these parts been released to manufacturing?
How can we effectively share this design data with our supplier?
Solution…
Implement PDM solutions to manage and communicate design data
Best Practice
© 2006 PTC8 Forward Looking Information Subject to Change without Notice
Manufacturing Standards and Quality
Do your designs satisfy manufacturing requirements?
Ways to validate manufacturing requirements
– Tolerance analysis
• We designed it, made it, will it fit together?
– Mold flow/filling
– Model checking/standards checking
• Bend lines too close to edge of parts, etc…
– Toolpath validation
As with design communication challenges, many of
these can be addressed without much difficulty….
© 2006 PTC9 Forward Looking Information Subject to Change without Notice
Product Fit/Tolerances
Don’t wait until an early production run to uncover tolerance stack up issues….
Problem…
Is this design toleranced appropriately?
Will the product fit together when manufactured?
How many of the units assembled will end up as scrap?
Solution…
Perform quick, up-front tolerance stack checking for critical dimensions
Best Practice
© 2006 PTC10 Forward Looking Information Subject to Change without Notice
Product Manufacturability
Many manufacturability issues can be addressed long before soft tooling….
Problem…
Is this design suitable to be molded?
Will there be sink marks or knit lines on visible surfaces?
Can I provide insight as to where the part should be gated?
Solution…
Use manufacturability design checking solutions
Design with manufacturability in mind as though for any other constraint
Best Practice
© 2006 PTC11 Forward Looking Information Subject to Change without Notice
Design Rules for Manufacturability
Apply rules checking tools to ensure basic design/manufacturing standards are adhered to
Problem…
Are standard sheetmetal thicknesses used?
Are allowable materials called out?
Are company naming conventions and standards adhered to?
Does the model contain small edges, inaccuracies, or other difficult to manufacture geometry?
Solution…
Use design rules and model checking solutions as gatekeepers in the design to manufacture handoff
Best Practice
© 2006 PTC12 Forward Looking Information Subject to Change without Notice
Designs satisfying design requirements
As a product is developed, a failure to address design requirements can lead to costly rework….
Aesthetic
Functional
Ergonomic
Leveraging traditional and non-traditional simulation
technologies can significantly reduce rework
© 2006 PTC13 Forward Looking Information Subject to Change without Notice
Aesthetic Requirements
Problem…
What will the product look like?
Will consumers like the color choices?
Are we satisfied with materials and texture choices?
Solution…
Photorealistic renderings of models can be used to validate design and stylistic decisions early in the development process
Pay attention to visual quality – details captured in design models will be leveraged in the aesthetic mockup
Best Practice
© 2006 PTC14 Forward Looking Information Subject to Change without Notice
Dynamic/Kinematic Requirements
Leverage Motion Skeletons to support top-down design techniques incorporating the correct rotational and translational degrees of freedom of your system
Best Practice
Problem…
Will the design move as intended?
Is this actuator sized properly?
Will these bearings support the loads in the assembly?
Solution…
Investigate kinematics before moving to physical prototyping
© 2006 PTC15 Forward Looking Information Subject to Change without Notice
Structural Requirements
Developing “mentoring” programs is the most effective means of proliferating use – broad based adoption in the design ranks pays the greatest dividends
Best Practice
“Best in class manufacturers are 63% more likely to provide CAD-embedded simulation to their engineers.”
Problem…
Is this design strong enough?
Will we have fatigue/durability issues?
Will the product bend/deflect too far?
Solution…
Apply functional simulation early and often in the design process to minimize surprises and late phase rework…
© 2006 PTC16 Forward Looking Information Subject to Change without Notice
Human Factors/Ergonomics
Don’t push ergonomics/human factors validation until the end of the design process. Uncover issues early that would in the past be identified during first build
Best Practice
Problem…
How will a user interact with the product? Will they be able to…
Lift a load?
See a control panel?
Reach a switch?
Operate a machine comfortably?
Solution…
Add a “Digital Human” to your environment
Include ergonomics validation from the very beginning of the design
© 2006 PTC17 Forward Looking Information Subject to Change without Notice
Real World Success Story
RollEase:
Integrated Product Development for Global Design and Manufacturing
© 2006 PTC18 Forward Looking Information Subject to Change without Notice
Conclusion
Application of PLM technologies can effectively reduce scrap and rework
Many root causes of scrap and rework can be effectively addressed
– Failure to satisfy design requirements
– Manufacturability issues
– Design Communication/Control
• The right data
• At the right time
• To the right people
As with many problems, addressing earlier is more cost effective than waiting….
© 2006 PTC19 Forward Looking Information Subject to Change without Notice
Thank You!
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