Honeywell PowerPoint 4.0 template

1
The Power of Product Knowledge
Leveraging Product Knowledge as a Competitive
Advantage!
Timely point-of-use information!
Reuse Infrastructure
Reuse Strategy
Preferred Parts
Modules
Product knowledge
Supplier/Mfg. Data
Cost Data
Cataloged Part Families
Schematic Search
Product Data List
Analysis Tools
Capability Assessments
Product Development Database (Web-Based LEAN TOOL)
Achieving Quantum Improvement Through Product
Knowledge and Informed Decision-Making
2
Modular Design Approach
Actuator Select Module
Regulator Select Module
Solenoid, Torque Motor Select from Data Base
Tubes Create New Part
Butterfly Shaft Select from Data Base or Create
New Part
Servo Body Select from Data Base or Create New
Part
Flow Body Select from Data Base or Create from
Template
Butterfly Plate Select from Data Base or Create
New Part
Create Reusable Building Blocks for New Product
Design
3
Results Modular Design Approach
Part Number Reductions

• Developed family of regulators
• Standard (4 Modules)
• High Vibration (2 Modules)
• Large Seat Style (3 Modules)
• CAD model created
• Module-level test developed to screen
• for leakage failures - eliminated a 15 failure
• rate during final product testing
• Current usage 8,000 per year
• Supplier developed to provide module at a
• 58 cost reduction over the pre-module
• configurations

38 Adjusting Screws Reduced to 4
52 Covers Reduced to 6
50 Diaphragms Reduced to 2
13 Springs Reduced to 4
12 Poppets Reduced to 3
12 Guides Reduced to 3
Regulator Module
4
Results Modular Design Approach
Before 11 different detail parts for 35 products.
After 1 sub-assembly for 35 products.
The Bonded Diaphragm Sub-Assembly

• Before
• 11 part numbers
• 8550 yearly purchases
• In-house bonding operation
• 4-hour cure time causes batch
• Poor fit, difficult assembly

• After
• 1 best practice part number
• 2,850 yearly purchases
• part is ready-to-use
• Flow enabled
• Snug fit, improved assembly

5
The Product Development Value Stream
Baseline Pneumatic Valve Product
Development Cycle Time 36-48 weeks
Engineering
Supply Chain
Product Definition and Drawing Package Creation
Procure and Assemble Hardware
Product Definition and Drawing Package Creation
18-24 Weeks
18-24 Weeks
Goal Pneumatic Valve Product Development Cycle
Time 6 weeks
Unless Improvement Could be Made in Reducing
Supply Chain Cycle Time, We Wouldnt Meet Our
Goal
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Linking Part Families With Suppliers
Reduce The Quantity of Existing Parts
Reduce Supply Base To Preferred Suppliers
Existing Supply Base
Preferred Parts
Existing Parts Portfolio
Preferred Suppliers
SP
SP
Eliminate Non-Preferred Parts
Eliminate Non-Preferred Suppliers
SP
SP
SP
SP
Part Family
Align Preferred Parts with Preferred Suppliers
Identical Strategies for Reducing the Number of
Suppliers and Parts
7
Housing Part Family
Aerospace Environmental Control Valve Product
Flow Body Housing

• Part family currently supported by 28 suppliers
• Family consists of 220 individual part numbers
• Predominantly castings - typically long lead
• procurement items

8
Creating Sub-Groups Within the Family
Housing Part Family
Casting
Brazed Sheet Metal Assy
(Same Breakdown as Casting)
Configuration 1
Configuration 2
(etc.)
Material 1
Material 2
(etc.)
(Sub-Group 1)
(Sub-Group 2)
Sub-Groups Based on Key Engineering and
Manufacturing Factors
9
Housing Sub-Grouping Strategy
Pre-Consolidation State (28 Suppliers)
Each Row Represents a Different Part Number And
Associated Data
Thick Black Lines Differentiate Sub-Group
Colors Differentiate Current Suppliers
Sub-Grouping Analysis Highlighted the Problem
of Multiple Suppliers Producing the Same Parts
!!!
10
Housing Sub-Grouping Strategy
Post-Consolidation State (5 Suppliers)
Each Row Represents a Different Part Number And
Associated Data
Thick Black Lines Differentiate Sub-Group
Colors Differentiate Current Suppliers
The Goal Was to Designate Only One Supplier for
Each Sub-Group
11
Feedback to Engineering
Software System Identifying Selected Partnering
Suppliers
Promoting the Concept of Concurrent Engineering
12
Housing Cost Profile
Each Data Point Represents a Different Part
Number
Region of Opportunity Value Engineering DFSS
Focus
REQUIREMENTS
COST / UNIT
Analysis of Common Parts Identifies Further
Improvement Opportunities
13
Benefits of Common Parts Analysis

• Identifies high cost - high dollar parts that
  represent
• the best opportunity for cost reduction and
  DFSS
• data collection opportunities
• Aids in identifying the should cost for new
  parts
• Based on the quantity, new part pricing should
  be in-line
• with other parts representative of the family
• From the suppliers perspective, common part
  analysis
• enables cost improvement ideas to implemented
  across
• the entire family
• Similar manufacturing approach
• Common tooling

14
Results

• Achieved a 28 Cost Reduction
• Consolidated the number of suppliers from
• 28 to 5 for the entire family
• Eliminated the supplier selection process for
• future (new) flow body parts
• Approximate 6 week throughput time savings
• Provided the foundation for successful data
  collection
• of key characteristics from suppliers to
  support
• Design for Six Sigma implementation

15
Guiding Ideas for VPD Improvement

• Work on Whats Important
• Pick the right projects and generate flow
• High value
• Match organizations core competencies
• Understand customer requirements and your
• products capabilities
• Concentrate the Work
• Minimize multi-tasking
• Staff teams with required / capable resources

16
Guiding Ideas for VPD Improvement

• Reuse Knowledge
• Do it once and dont lose it
• Reuse product and product information
• Provide easy access to information
• Learn as much as early as possible
• Identify and assess risk, determine mitigation
  quickly
• Resolve the biggest risk area first