Reducing Scrap and Rework John Buchowski Director, MCAD Product Management PTC.

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


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


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

Email

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


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?


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


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


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….


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


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


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


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


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


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


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…


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


Real World Success Story

RollEase:

Integrated Product Development for Global Design and Manufacturing


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….


Thank You!

Reducing Scrap and Rework John Buchowski Director, MCAD Product Management PTC.

Documents

information subject

notice scrap

notice plm

notice manufacturing

design databest practice

product development

core causes of scrap

edge of parts