Manufacturing companies are under increasing pressure to ensure product quality and reliability, make better use of production resources, and to ensure delivery precision if they are to stay competitive in today’s global market place.
It is not unusual for product development projects to focus on functional prototypes in order to verify the concept. However, new problems can arise if the design has not been industrialized prior to the start of serial production.
Growing globalization places more demands on outsourcing, which in turn places demands on material selection and specifications, choice of tools and test equipment, verification and validation and quality assurance of suppliers, etc.
Having a product that is not industrialized leads to quality defects and undesired adjustments deriving from the product’s tolerance chain and which will require fixtures and complicated tests.
In turn, suboptimal production results in higher product costs and an inability to meet delivery dates.
This type of situation often results in re-engineering at a time when it is difficult to make changes, or when resources have already been dedicated to new projects.
Producibility, and how production processes will be controlled, need to be considered early on in the product design phase in order to ensure successful serial production.
Design for Assembly (DFA) and Design for Manufacturing (DFM)
Analyze the design of the product with the intent of optimizing it for production, but without affecting the function. Reducing the number of parts in a product – and reviewing the ease of assembly of each respective part – ensures more efficient production with fewer fixtures, adjustments, testing, and quality deficiencies.
Process Failure Mode Effects Analysis (PFMEA)
Analyzing the failure mode effects of the various production processes can uncover potential risks, so they can be corrected before the product goes into serial production.
It is obvious that you need the right parts in order to produce your product – but it is equally important to have control over your own production. We can assure the quality of both your suppliers and your internal production.
Using a ‘Lean Manufacturing’ perspective, we can carry out a situation analysis of your production in order to identify improvements, leading to greater efficiency, balancing, less waste, shorter lead times, and more efficient inventory management.
Benefits for your organization
- Better resource usage
- Shorter lead times in production
- Less documentation
- Reduced product costs
- Reduced lifecycle costs
Benefits for purchasing, planners, logistics
- Fewer suppliers
- Reduced inventory costs
- Less receiving inspection
- Simplified production control
- Fewer parts, resulting in a fewer fixtures needed
- Reduced scrap and rework
- Improved product tolerance chains