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Simultaneous product and production
development at Philips Turnhout
Hans Van Reusel - Philips Innovation ServicesGert Janssen - HID product development manager
Accelerate your innovationIntroducing Philips Innovation Services
2
Accelerate your innovation
Philips InnovationServices
Concept Creation Support
A service provider
Industry Consulting
Sustainability, Safety & Health
Quality &Reliability
EquipmentDevelopment
Prototyping & Small Series
Product & ProcessDevelopment
Industrialization
3
11/11/2013
PRODUCTIONPRODUCT DEVELOPMENT Philips Innovation Services GTDM
IndustrializationThe link between Product Development and Production
IndustrializationActivities and Competences
Concept
� Product co-
development
� Research
� Feasibility
studies
� Concept creation
� Consulting
� Lean solutions
Specification
� Industrial Setup
� Manufacturing
process
development
� Design for Six
Sigma
� Design for
manufacturing
� Prototyping
studies
� Concept freeze
Engineering
� Mechanical,
electrical and
software design
� FEM analysis
� System
integration
� Project
management
� CE - Safety
� Ergonomics
Realization
� Global sourcing
� Assembly
� Start & ramp up
� Training
� Repeats
Service
� Product range &
capacity
extension
� Productivity
improvement
� Spare parts
management
� Relocation
A track record of successful innovations …
Value Proposition Creation &Advanced Development
Life Cycle Management
• Innovation Strategy • Landscaping & Ideation • Innovation Planning• Programming
• Value Proposition Creation• Technology & Function Creation• Architecture & Platform Creation
• Product Development & Industrialization
• Market Introduction
• Feedback• Maintenance• End Of Life
Product & Services Development &Market Introduction
Ideation & Innovation Planning
… aligning industrialization with the Philips Lighting Idea to Market process (I2M)
7
Why product & manufacturing specialists should
cooperate early on
• Product & process/manufacturing specialists together can find the optimum
balance between product performance and manufacturability:
– Materials selection => processability
– Component design => production cost, ease of assembly
– Testing strategy => how to monitor/control product quality
– …
• Early cooperation allows to fix
problems faster and at lower
cost
Design for Six Sigma (DfSS) embedded in PRI
Design-for-Six-Sigma is: “Right-Design-Right”
• a structured method (D-I-D-O-V),
• to design proactively products and processes,
• of a predictable robust quality,
• based on quantified specifications,
• agreed with customers and suppliers.
Define
Identify Design Optimize Verify
Monitor
Measure Explore Describe Improve Control
DfSS: a proactive method to design new products
MEDIC: a re-active method to improve existing products
8
9
The different stages of DFSS (DIDOV)
Mfg. Process CTQ Specs
Component CTQ Specs….
Subassembly CTQs..…
Subsystem Level CTQs…..
System Level CTQs…..
Design
Cp
Cp
Cp
Cp
Cp
Optimize & Verify
Voice of the Customer Needs
System Level Requirements
Subsystem Level Requirements
Subassembly Level Requirements
Component ‘Critical to Quality’ Requirements
Mfg. Process Requirements
Define & Identify
Example Salt dosing new gen CDM
11
GEN4 …. Complexity : Accent->Ultimo
1. Salt
2. Feedthrough
3. connection
4. Seal
5. ZUP
6. Antenna
Case salt doser (Bart L)
• Breakthroughs needed
• Size
• Accuracy
• ….
Projectname
MPCP Project Leader
Project Plan: ECP/MPCP PCP
MS-3 MS-2:
MS-2 mrt '09 MS-1:
MS-1 mrt '09 MS0:
MS0 okt '08 mrt '10 MS2:
MS1 jan '09 mrt '10 MS3:
MS2 jul '10
MS2+
MS3 jun'11
Processes Transl. customer
wishes to key end
product spec's
Colour process
steps: g(reen),
o(range), r(ed)
Alternative
processes
evaluated
Risk Maturity
Grid filled-in
Q-map Parameter
List
DoE's done Tolerance
analysis
done
Cmk at
required level
Parameters
future control
plan
identified
Required
%R&R
achieved
Risk
Maturity
Grid up-to-
date
SPD
report
ready
mercury dosing o ok ok ok ok ok ok for LTD ok ok ok 95%
salt dosing o ok ok ok ok ok ok ok ok ok 90%
plug dosing r ongoing ok ok 80% 75% ok ongoing
SPD step finished? (yes = "ok")
Processes Verify parameter
settings
Process
FMEA
Control
plan finished
Verify %R&R Short term
Cpk
Control charts
available
Long-term
Cpk
OCAP's
available
mercury dosing ok ready ready 12% 1.45 ok 1.32 80%
salt dosing ok ready ready 8% 2.13 ok 1.86 75%
plug dosing ok ready ready 5.60% 1.89 ok 1.64 60%
SPD step finished? (yes = "ok")
SPD Step 7 - 8
Perform verification on mechanised equipment
from MS1 to 2
SPD Preparation Phase SPD Step 1-3
Describe and identify
from MS2 to 3
ok
SPD Step 9 - 10
Assess control
SPD Step 4 - 6
Analyse and
Optimise
ok
SPD Step 7 - 8
Perform verification on test equipment (PMO)
SPD completion score
Ulimo Enter data in yellow fields only!
Ward Cottaar
from MS -1 to 0
IndustrializationMPCP: how?
•Define assignment
•Identify critical processes
•Evaluate multiple alternatives
•Create risk overview
•Make proces descriptions
•Set-up proces flow
•Set-up Qmap / critical parameter
overview
•Extensive testing (DoE) of identified
critical parameters
•Define proces windows
•Build tolerance analysis
•Validate chosen solution
•Define production- & test- equipment
•Update risk overview
•Verify on final production set-up
•Define final settings
•Measure performance
•Monitor long term performance
• MPCP philosophy ingrained in our organization for over 10yrs
• Green and Black belt training programs support this way of working
• MPCP philosophy crosses boundaries product development –machine creation
Processes Transl. customer
wishes to key end
product spec's
Colour process
steps: g(reen),
o(range), r(ed)
Alternative
processes
evaluated
Risk Maturity
Grid filled-in
Q-map Parameter
List
DoE's done Tolerance
analysis
done
Cmk at
required level
Parameters
future control
plan
identified
Required
%R&R
achieved
Risk
Maturity
Grid up-to-
date
SPD
report
ready
mercury dosing o ok ok ok ok ok ok for LTD ok ok ok 95%
salt dosing o ok ok ok ok ok ok ok ok ok 90%
plug dosing r ongoing ok ok 80% 75% ok ongoing
SPD step finished? (yes = "ok")
Processes Verify parameter
settings
Process
FMEA
Control
plan finished
Verify %R&R Short term
Cpk
Control charts
available
Long-term
Cpk
OCAP's
available
mercury dosing ok ready ready 12% 1.45 ok 1.32 80%
salt dosing ok ready ready 8% 2.13 ok 1.86 75%
plug dosing ok ready ready 5.60% 1.89 ok 1.64 60%
SPD step finished? (yes = "ok")
SPD Step 7 - 8
Perform verification on test equipment (PMO)
from MS -1 to 0
SPD Step 7 - 8
Perform verification on mechanised equipment
from MS1 to 2
SPD Preparation Phase SPD Step 1-3
Describe and identify
from MS2 to 3
ok
SPD Step 9 - 10
Assess control
SPD Step 4 - 6
Analyse and
Optimise
ok
IndustrializationMPCP: example
Processes Transl. customer
wishes to key end
product spec's
Colour process
steps: g(reen),
o(range), r(ed)
Alternative
processes
evaluated
Risk Maturity
Grid filled-in
mercury dosing o ok ok
salt dosing o ok ok
plug dosing r ongoing ok
SPD Preparation Phase
ok
Bulk
200µm 800µm
One by one
Probability
5 OK
4 24, 25NOK but
will be
fixed
33, 6, 10,
31
2, 5, 13,
29
9, 12, 23,
26, 27, 30
Show-
stopper
2 21 14 8, 22, 28 4
1 15, 32 1, 18 Severity
1 2 3 4 5
Nr Back-up Scenario
1 snelle vervanging van naald mogelijk maken
2 meerdere doseurs plaatsen
3 product beweegbaar opstellen
4 trommeldoseur (enkel voor grotere gewichten)
5 meerdere doseurs plaatsen
6 stofzuiger voorzien in de box
7
8 voice coils ontwerpen voor grotere slag
9
10
11
29
30 instructies aan operator
Salt dosing
tolerantietrein in constructie
optimaliseren?
doseersnelheid opvoeren (bv door
gebruik van buffer)
naald snel versleten
bij grotere gewichten, meerdere
doseurs nodig
vervuiling van machine
vision onnauwkeurig
redesign nodig
doseur werkt niet
plakkende bollen, moeilijk te doseren
slechte producten in de markt
de-ionisatie apparatuur plaatsen
Doseur haalt snelheid niet
zout morsen
invloed van trillingen van machine
op werking doseur (vision)
LINAX heeft zich nog niet bewezen
hoekfout naald
aanpassing doseur noodzakelijk
doseersnelheid opvoeren (bv door
gebruik van buffer)
extra beweging van naald voorzien
controle bij eccentriciteitsmeting?
flexibel zoekgebied uitwerken
juiste materiaalkeuze
opvangbakjes op machine worden
voorzien
betere koppelingen
meerdere doseurs nodig
positionering ZUP nog niet
gedefinieerd
zout morsen
voice coil uitgewerkt
naald loopt tegen ZUP-wand en slijt
snel
zoutpotjes specifiek maken per
zout
zout verschillende diameter geven
per type
statische ladingen zoutbollen
zoutvermenging
werkt doseerprincipe voor alle
zouttypes? (AlI3)
botsdetectie naald wordt geactiveerdvastlopen naald in ZUP door braam
of stof
invreten op materiaal machine (vooral
AlI3)
Piëzo units in Argon omgeving
aanpassing doseerprincipe of ander
doseerprincipe nodig (is er niet!)
Counter Measure
betere positionering ZUP en naald
juiste zoutgewichten nog niet
bekend
slijtage van naald tegen ZUP-wand
Risk Consequence
Probability:1: failure unlikely, <1 ppm2: relatively few failures, 10 ppm3: occasional faiures, 1 in 10004: frequent failures, > 1 in 205: failure inevitable, > 1 in 3
Severity (customer effect):1: no noticable effect2: aesthetic failure, defect noticed by discriminating customers3: item operable but comfort/convenience is compromised. Most customers dissatisfied.4: item inoperable. Customer dissatisfied.5: unsafe operation/ non-compliance with regulation
Severity (manufacturing/ assembly effect):1: no or slight inconvenience to operator or aoperation2: a portion of the products has to be reworked with minimal effort3: a portion of the products has to be reworked with moderate effort4: all products have to be scrapped or reworked with great effort5: failure may endanger operator
Gage R&r with limits +/-1µm:
Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
Total Gage R&R 0,0000224 0,000135 0,10 4,49%
Repeatability 0,0000174 0,000104 0,08 3,47%
Reproducibility 0,0000142 0,000085 0,07 2,84%
Operator 0,0000000 0,000000 0,00 0,00%
Operator*Produktnumme r 0,0000142 0,000085 0,07 2,84%
Q-map Parameter
List
DoE's done Tolerance
analysis
done
Cmk at
required level
Parameters
future control
plan
identified
Required
%R&R
achieved
Risk
Maturity
Grid up-to-
date
SPD
report
ready
ok ok ok ok for LTD ok ok ok 95%
ok ok ok ok ok ok ok 90%
ok 80% 75% ok ongoing
SPD Step 7 - 8
Perform verification on test equipment (PMO)
SPD Step 1-3
Describe and identify
SPD Step 4 - 6
Analyse and
Optimise
ok
Verify parameter
settings
Process
FMEA
Control
plan finished
Verify %R&R Short term
Cpk
Control charts
available
Long-term
Cpk
OCAP's
available
ok ready ready 12% 1.45 ok 1.32 80%
ok ready ready 8% 2.13 ok 1.86 75%
ok ready ready 5.60% 1.89 ok 1.64 60%
SPD Step 7 - 8
Perform verification on mechanised equipment
SPD Step 9 - 10
Assess control
5.57
5.575
5.58
5.585
5.59
5.595
5.6
5.605
5.61
5.615
Weight
result
LRL
LCL
Target
UCL
URL
Mean: 5.5995 StDev: 0.0018 Cpk: 1.9406
Pilot Setup
Process
Semi-automation
Full automation (*)
Step 1
Step 2
Step 3
Process flow Ultimo: maturity processes & equipment should be in phase with product life cycle
(*) Level of automation = f(TCO)
Example Ramp up of the new platform
17
Hoe het begon…
GEN4 Dosing & Sealing Glove Box
www.openmanufacturingcampus.com