NACAAM Supporting Local Tooling CLUSTERING 6 APRIL 2017

Transcription

1 NACAAM Supporting Local Tooling CLUSTERING 6 APRIL 2017

2 Our Purpose CLUSTER PURPOSE Proactive thought leadership in creating an environment for Development, Growth and Prosperity of tool manufacturing in South Africa Vision >50% tools manufactured in RSA by 2025 Brand Tooling South Africa's future Values National Interests come first Long term thinking dominates Collaboration Cooperation Commitment is a reputation bond

3 CONDITION for Industry to place orders on SA companies for TOOLS: 1. Contract with Full Service Provider Project Management - One face to Client 2. Tool Design (Right first time) 3. Delivery (Lead times, commitment dates) 4. Cost (Internationally Competitive) 5. Quality (Internationally competitive) 6. Manufacturing / Volume Capacity

4 CLUSTER CORE VALUES Transparency Commitment Innovation Service delivery Initiative Quality

5 Concept PROCESS FLOW Simulation Design Review Identify critical areas CAD & 2D conversion Distribute PM Timing Cost Mng Risk Mng Metrology Reporting Trails & Optimisation Trails & Optimisation Commission, PPAP, Handover 5

6 RFQ Based on customer specific requirements Based on tool manufacturing standards International Automotive Fully broken down package with all tool systems NDA s & Manufacturing agreements

7 CONCEPT TOOLING TYPE (EXACTLY HOW THE TOOL WILL WORK) CONCEPTIAL DESIGN OF MOULD SHEETMETAL PLASTICS JIGS & FIXTURES ALUMINIUM CASTINGS Tool line-up Blanking tools Forming tools Progressive tools Hot Runner Mould flow analysis Core pulling Semi/Full automatic Post processing Assembly Orientation of components and cavities Fixture type: Pneumatic Mechanical Component sensing modules Trimming tools Mechanical/Hydraulic Orientation Cavities Post processing Machining Jigs Flow analysis Core pulling

8 DESIGN Based on Machine sizes and capability Based on International Automotive mould making standards

9 SIMULATION Mould flow analysis Prototyping

10 DESIGN REVIEW Customer Designers (Selected board) Process Engineer SQA Engineer APQP process followed from project kick off (Advanced Quality Prod planning) Identification of critical areas and allow for optimisation in design Could have numerous design reviews for downstream processes

11 TOOLING CAPABILITIES Small to Large size tooling Plastic injection moulds; Sheet metal progression tooling; High pressured aluminium die cast moulds; Jigs and checking fixtures; Special purpose machinery; Prototyping; Product design and development; Tool Design & Manufacturing Process/Assembly line design All types of tooling Manufacturing efficiency improvements Technical Consulting & assistance CAD/CAM DESIGN, CAD AND SIMULATION SOFTWARE: Access to all softwares

12 MOULD/TOOL DESIGN 2D DRAWINGS SPECIFYING TOLERANCES & SPECIFICATIONS 2D drawings to be prepared with tolerances Include full process instruction, materials to be used, stress relieving etc Full metrology report Distribution of work amongst toolmakers

13 CLUSTER MANAGEMENT Project Management Timing Management Cost Management Risk Management Full understanding of all Quality Systems & Processing requirements Assist with ISO 9001 implementation Metrology of critical sizes Upskilling get all to work the same Supplier development Report management Design review team

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15 MANUFACTURE Facilities will be audited to work to quality standards that comply with Automotive requirements Processes to be monitored Timing plans to be updated and communicated to customer with visual reports

16 TOOL TRAILS & OPTIMISATION This will happen at nominated toolmaker/1 st tier supplier for part trails & provide 1 st set of parts for measurement and fitment Every project will accommodate for at least 2 loops of optimisation to allow 100% dimensional accuracy still within required timing

17 COMMISSIONING & HANDOVER Process Engineers to ensure optimum production parameters set and process is constant Dimensional reports on product Allow easy fault finding after commissioning if problem found with mould (Processing parameters, tool inspection or material issues) Critical component list (spares) to be supplied (Hot runner elements, thermocouple, ejector pins etc) Maintenance

18 CLUSTER FUNCTIONS Project Management (Investigations, Pre-feasibility studies, Planning, WBS structures, Project Risk Management, Scope of work and specifications, Time Management, Cost Management, Project close out and lessons learnt.) Design Engineers Design, simulation SQA Engineers Toolroom processes, procedures and document control Process Engineers Optimum process parameters for production handover

19 WHAT IS DIFFERENT? Now full package is offered from design to manufacture (A-Z solution) Fully documented and managed designs Checklists allowing easy follow through on designs Visual management & constant interaction 2D drawings with clear set tolerances for deliverables Total Quality Management

20 Current annual South African tooling market worth R15-18 billion 88% of which is out sourced to China, East & Europe Only 12% produced locally due to timing, planning, cost and quality constraints We are working with TASA to create a tooling cluster to reduce the % tooling outsourced to the rest of the world SOUTH AFRICAN TOOLING SA tooling income local tooling: R 2.16 bn Potential tooling income: R 9 bn by 2025

21 DRIVEN BY HTSA ENGINEERING TEAM HellermannTyton South Africa is a subsidiary of the HellermannTyton Group which has operations globally in 37 countries, employs over 4000 people and generates revenue in excess of 700 million Euro We have also part of the international design & innovation team (Only 5/37) Germany, France, UK, USA and now SA Product Design, Development and Manufacturing is a key focus and the local facility utilising state-of-the-art CNC machines, plastic injection moulding machines, extrusion machines and printing equipment to produce world class products in compliance with international quality standards

22 GLOBAL PLAYERS December 2015 taken over by Delphi automotive Headquartered in UK, it is on of the world s largest automotive parts manufacturers Global Data management systems A Web-based Product Data Management (PDM) system that supports geographically dispersed teams while managing critical processes such as content, change and configuration management. This allows you to create and manage product structure views such as As-Designed and As-Planned, thereby optimizing configuration management. Features and Benefits Global access Enables Web-based access to a current product data management repository Seamless connections Enables access to multiple mechanical/electrical CAD applications, embedded software tools, desktop applications and ERP systems Prevents design errors Controls and automates product development processes, improving quality and reliability Improved innovation Facilitates rapid development of new products with powerful configurations tools Complete integration

23 TYPICAL SINGLE TOOL ROOM EQUIPMENT 2 x NC Spark Eroders 2 x CNC Spark Eroders 1 x Wire Cutter 3 x 3 Axis CNC Milling Machines 1 x Surface Grinders 2 x CNC Lathes 3 x Toolmakers 2 x Apprentices NEW CAPACITY PROPOSAL AND GROWING Our capabilities are NOW as follows. In excess of 50 CNC Machines including 5 axis maching up to 2000x3000mm Surface grinders x 12 Spark Eroders x 16 Lathes x 14 Laser welding CNC Turning 250mm DIA x 2000mm 3D Measuring system 2000mm x 6000mm Qualified toolmakers = 42 Designers = 5 Toolmaker apprentices = 18

24 CAPACITY

25 Networking facility for the toolmaking fraternity to share views on retaining tooling revenue, training and development of tool makers and new tool making technology Tool manufacture Die Set and component supplier Process Efficiency Mould flow analysis Hot runner systems Tool design & Tool Manufacture Plastic Injection moulding capabilities Mouldflow analysis Supplier development Product Design & Development Tool manufacture Tool Design & Project Management solutions Mould flow analysis Technical consultants Supplier development Product Design & Development Tool design capabilities Manufacturing & Engineering consultants Tool Design & Manufacture Autoform Global Technical Partner (MOU) Design responsible

26 IMPACT (VALUE) Economic Growth Localisation Job Creation Job retention Growing of industry Upskilling industry Local toolmaking support for OEM s

27 SUCCESSES MBSA BRACKET TOOL LOCALISTION

28 SUCCESSES MBSA BRACKET TOOL LOCALISTION

29 SUCCESSES MBSA BRACKET TOOL LOCALISTION

30 SUCCESSES MBSA BRACKET TOOL LOCALISTION

31 SUCCESSES MBSA BRACKET TOOL LOCALISTION

32 SUCCESSES MBSA BRACKET TOOL LOCALISTION

33 TOOL 3D MEAUREMENT REPORT

34 PART 3D MEAUREMENT REPORT

35 RESULT World-class timing (12 weeks) World-class quality (Through hardened) World-class Costs Cluster collaboration & Management Localisation (APDP benefits) Job creation

36 NEXT STEPS Create Volume Capacity Pool knowledge Supplier Audits

37 AUDIT NEW STANDARD Design capabilities Machining capabilities Project Management (delivery times) Costing structures Machining processes Machine maintenance e.g Backlash checked on machines Quality management dimensional reports of previous projects Management system Internal go/no go processes

38 THANK YOU ANY QUESTIONS?