Design for Production: how to make it happen Jan Verbeek Partner/senior consultant ADSE P.O. Box 3083 | 2130 KB Hoofddorp | The Netherlands | www.adse.nl © 2006 ADSE B.V. Contents • Introduction • Barriers – Cultural – Practical – Thus…. • How to remove the barriers • Conclusions 2 © 2006 ADSE B.V. The world of ADSE ADSE is an independent consulting and engineering company. Active in Aerospace, Defence, Rail and Infrastructure Our combination of a systematic approach and technical knowledge is crucial Founded in 1996, currently employs about 75 people, turnover 2005 7.1 M€ 3 © 2006 ADSE B.V. Introduction to Design for Production • Concurrent engineering and DFMA methods are well known – Use integrated product teams – Use 3D CAD tools and their process planning ”relatives“ – Use DFMA, Design for 6 Sigma, etc, methods and tools • So, why is it so difficult? 4 © 2006 ADSE B.V. Leverage on Expenditure 5 © 2006 ADSE B.V. Introduction to Design for Production • Many barriers: – Cultural – Practical • How can we remove these barriers? 6 © 2006 ADSE B.V. Time is always running out 7 © 2006 ADSE B.V. Cultural barriers Engineers versus (business) managers • The management drive for efficiency conflicts with the technical drive for upfront analysis {often with unspecified results} • The difference between the “company world” and the real world • Don’t believe the 3D magic: what you see is not what you get! • Timing of a decision is essential: delaying is often a sensible option for management, but not for technical people 8 © 2006 ADSE B.V. An decision makers nightmare 9 © 2006 ADSE B.V. Cultural barriers Designers versus production specialists • Designers think evolving or in iterations, production specialists think linear • “Real” communication is rare • Production specialists are reluctant to give comments before Designers have formulated their ideas 10 © 2006 ADSE B.V. Practical barriers • Physical distance (internally, but specially with suppliers) • Systems, schedules and procedures obstruct open dialogue • Sales and Management people are not available during a design phase • Difficult design issues often require early decisions for investments or long lead items, • How do you produce the right information at the right time? 11 © 2006 ADSE B.V. Thus: production requirements/constraints ….remain unclear to designers: • The communicated requirements are either very high level (management) or very detailed (specialists) • A lot is hidden in standards ….or are not communicated at all: • Out of some sort of negotiation strategy or personal hidden agenda • Because the owner of the requirement doesn’t know himself 12 © 2006 ADSE B.V. How to make it happen: remove the barriers Break the mould ! Find people with the right attitude Start with an integrated approach for Design for Production and use Systems Engineering principles Look at the product and production (development) processes 13 © 2006 ADSE B.V. Integrated process approach 14 © 2006 ADSE B.V. How to make it happen: remove the barriers Follow up and start early in the development process; in parallel with R&D and market research studies Connect the design and the production development process through integral planning and solve the time squeeze Ask the right questions on the right moment An example 15 © 2006 ADSE B.V. Solve the time squeeze (1) Design Design Definition Full Scale Development Detailed Design RR KO PDR DRR CDR FAI PR EPE SR Top Level Reqs. Design Activities Design Concept Stress Activities Design Principles M&P Activities Product Breakdown Structure Certification Activities Module SAM Plan Start SAM Module Initial DMU Design Integration Component 1 3D-models Eng. Release Notes Plan Start Modeling Components Production BOM Preliminary Stress Report Loads Input Component 2 3D-models Certification Stress Report Eng. Release Notes Production BOM Preliminary Stress Report Component N 3D-models Product Definition Component 2 Certification Stress Report Eng. Release Notes Production BOM Preselection of Materials Product Definition Component 1 Preliminary Stress Report Product Definition Component N Certification Stress Report Proces Specifications M&P Reqs. Draft Material Specifications Qualified Material Specifications Draft Process Specifications Qualified Process Specifications Proof of stability & reproducibility Certification Basis 16 Materials & Processes Selected PMCC MCC Certification Plan (concept) Certification Plan (final) Certification Reports Structural Test Specifications Test Reports © 2006 ADSE B.V. Solve the time squeeze (2) Production Plan Start Parts Production Plan Availability Bought-out Parts Plan Start Assy Product & Production Process Definition Product Breakdown All Parts Manufacturing is preceded by Material Supply Plan Start Assy Delivery to Customer Materials Supply Bought-out parts Parts manufacturing Assembly Non-Recurring Order Planning: - Entry into ERP-system - Assy/Part Plan Data Recurring Order Planning: - Production Inspection Record / Production Sheet - Production Planning (Availability) 17 © 2006 ADSE B.V. Solve the time squeeze (3) Connect them Design Definition Full Scale Development Detailed Design KO RR PDR Industrialization DRR CDR Maturity FAI EPE PR SR Top Level Reqs. Design Concept Design Principles PBS Module SAM Initial DMU Design Integration Component 1 3D-models Preselection of Materials Product Definition Component 1 ERN's Production BOM Proces Specs Draft Material Specifications Qualified Material Specifications Draft Process Specifications Qualified Process Specifications M&P Reqs. Material & Process Selected Plan Materials Availability Tooling Qualified Materials & Processes Plan Tooling Availability Product Definition Last Input Product Definition Tooling Specification Selection & Contacting Tooling Engineering Product Definition Tooling Manufacturing & Installation Tooling Qualifcation Last Input Product Definition Specification Selection & Contracting Qualification Engineering Material Selection Manufacturing & Delivery Plan Availability Bought-out Parts Bought-out Parts Product Definition Last Input Product Definition Specification Selection & Contracting Qualification Engineering Delivery to Customer Manufacturing & Delivery Production Logistics 18 Product & Production Process Definition Product Breakdown © 2006 ADSE B.V. Conclusion In the famous last words of a fellow project manager (at completion of his multi million euro project right before the gates of hell): Don’t assume anything!!! P.O. Box 3083 | 2130 KB Hoofddorp | The Netherlands | www.adse.nl © 2006 ADSE B.V.