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John Glenning's Process Development and Manufacturing Strategy
1.
© John Glenning
2008© John Glenning 2008 John Glenning's ProcessJohn Glenning's Process Development-Development- Manufacturing StrategyManufacturing Strategy John GlenningJohn Glenning December 2, 2008December 2, 2008
2.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: 1. Resolve critical problems Eliminate all problems that cause the product to fail during the manufacturing process or prevent the product from operating functionally 2. Meet product specifications Successfully build early hardware for the down stream processes and allow for product testing 3. Eliminate precision problems Minimize variability in the incoming material and the manufacturing processes in space and time 4. Optimize the manufacturing process using Designed Experiment • Optimized Conditions (eliminate accuracy problems) • SPC Measure all process parameters and mid-stream product parameters to identify product variables to control chart and the process variables to adjust
3.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: 5. Develop High Manufacturing Capability Improve the Cp & Cpk for all final product variables at all locations to 2.0 or greater 6. High Yields Cp & Cpk for all final product variables at all locations to 2.0 or greater directly lead to high yields. 7. Eliminate Mass Inspection Cp & Cpk for all final product variables at all locations to 2.0 or greater allows for eliminating mass inspection and replace with sample inspection 8. Qualify the manufacturing process Stress the manufacturing line by building more product to tighter standards over a shorter period of time. This will identify manufacturing problems that may occur during full scale manufacturing
4.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: 9. Reduce Cycle Time Find sources in process set-up, manufacturing operations and process breakdown & clean-up that hurt capacity utilization 10.Improve Equipment Up-time Develop a preventive maintenance plan that addresses sources of equipment crashes and be prepared to do preventive maintenance during unplanned downtime 11.Reduce Manufacturing Costs Identify and qualify alternative incoming materials that maybe used, adjust the processes to allow for increased manufacturing speed without sacrificing quality and look for opportunities to reduce the manpower to operate the equipment
5.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Consistently track key manufacturing metrics • Capability (Quality) • Cycle time • Equipment up-time • Total Manufacturing Cost Incoming material, capital depreciation, labor, maintenance and engineering support • It cost 10 times more to solve problems in manufacturing than in development and it cost 10 times more to solve problems in development than in research The earlier problems are identified and resolved, the less it costs the business
6.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Capability is the standard to determine the ability of the manufacturing process to build the product so it consistently meets customer specification. This needs to be done for all specified product features by location • Cp = (USL – LSL)/6σ & Cpk = lesser of (USL - µ)/3σ and (µ- LSL)/3σ • Cp & Cpk < 1.00: Process is “Not Capable” • Cp & Cpk ≥ 1.00 for features at all locations: Process is “Capable” • Cp & Cpk ≥ 2.00 for features at all locations: Elimination of mass inspection • Cp & Cpk ≥ 3.00 for features at all locations: World Class Manufacturer
7.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Repeatability Studies for both product and process measurement systems: Is the measurement error significantly less than the differences you are trying to detect? • When problems are identified, determine if they are accuracy or precision problems. This is critical because the solutions are different. Accurate but not precise Precise but not accurate • Cp & Cpk will help to identify the accuracy & precision problems • First solve the precision problems because they can mask accuracy problems • Consistent incoming material in space & time • Minimize process variability in space & time • Designed experiments are excellent at solving accuracy problems
8.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Understanding Manufacturing Processes • Hold your suppliers to meet your material specifications in space & time • Track & identify incoming material lots to your product • Retain samples of incoming material for future analysis • Capture time-stamped processing data in a database • Time stamp product when run in each process • Measure product mid-stream • Correlate incoming material lots & processing data to interim and final product attributes • This does not demonstrate cause & effect • Cause & effect is demonstrated when the problems can be created at will
9.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Yield Improvement Plans • Do not develop yield improvement plans based on inspection reports • Inspection is “First Defect Found” • First Defect Found-finds the easiest defect to inspect for, not the most common defect • Yield improvement plans need to be based on defect unlayering • Start from end of the process-biggest impact on costs
10.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Cycle Time • Minimize Cycle Time • Eliminate or minimize “non-value added process” like set-up • Find the slowest step and work on it until it is no longer the slowest step • Low variability in cycle time • Requires more starts to ensure customer shipments are not missed • Inventory unneeded finished products • Adds significant costs • “Tail chasing sessions”-attack the “problem of the day”
11.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy Process Development Philosophy: • Improve Equipment Up-time • Product Change-overs • Keep required tools & materials at the equipment • Planned downtime-maintenance & upgrades • Unplanned downtime-machine crashes • Plan for unplanned downtime • Be prepared to do maintenance • Cost • Track on a continual basis • If costs are highly variable, profitability cannot be assured • Difficult to reduce manufacturing costs
12.
© John Glenning
2008© John Glenning 2008 Process Development-ManufacturingProcess Development-Manufacturing StrategyStrategy End of Presentation
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