Production Preparation Process

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Production Preparation Process

• The SMS Technologies Quality Management System
  includes
• ISO 9001, AS9100, ISO 13485, and ISO/TS 16949
• They All Include Product Realization
• Advanced Product Quality Planning
• Production Preparation Process
• Production Part Approval process

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APQP, Flow Charting, Process FMEA, Control Plan,
3-P PPAP

• APQP Advanced Product Quality Planning
• Build 1st-time Quality into the Production
  Process
• FMEA Failure Mode Effects Analysis
• Minimize Risk (DFM, DFT Mistake-Proofing)
• 3-P Production Preparation Process
• Build to Customer Demand Beginning at Launch
• PPAP Production Part Approval Process

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PRODUCT QUALITY PLANNING TIMING CHART
CONCEPT INITIATION/ APPROVAL
PROGRAM APPROVAL
PROTOTYPE PILOT
LAUNCH
PLANNING
PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
Planning INPUTS Planning OUTPUTS
Product Design Dev. INPUTS Product Design
Dev. OUTPUTS
Process Design Dev. INPUTS Process Design
Dev. OUTPUTS
Product Process Validation INPUTS
Product Process Validation OUTPUTS
Production INPUTS Production OUTPUTS
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SEI Process Flow Diagram
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Process Failure Mode Effects Analysis
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Proto-type, Pre-launch Production Control Plans
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Operator Work Instructions
Work Instructions with applicable drawings, etc.
are developed for each material transformation
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The Key Linkages for Customer Special
Characteristics
Process Flow Chart FMEAs
Control Plans Operator
Instructions PPAP
Core Tools Applications
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Defining Balancing The Cell
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Calculating Takt Time

• Total Shift Hours 8 X 60 min. X 60 sec.
  28,800 seconds
• -2 - 15-minute breaks X 30 min. X 60 sec. 1,800
  seconds
• -Start-up Shut-down 15 min. X 60 sec. 900
  seconds
• Available Work Time 26,100 seconds

Takt Time Available Work Time / Customer Demand
(units) TAKT TIME 26,100 Seconds / 50 Units
522 Seconds TAKT TIME 522 Seconds / 60 8.7
Minutes Build a cell that will produce one unit
every 8.7 minutes!
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Defining Balancing The Cell
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Defining Balancing The Cell

• Until learning curves been achieved, work
  portions are allowed to vary slightly around the
  takt time until conducting further studies

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Preliminary SEI Cell Floor Layout
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Varying The Cell Volume

• Scaling Volume by Adding Shifts

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