Presented by: Chantelle Phillips HellermannTyton SA Engineering 19 July 2018 GEM INNOVATE COLLABORATE STANDARDIZE

Transcription

1 Presented by: Chantelle Phillips HellermannTyton SA Engineering 19 July 2018

2 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-ofthe-art CNC machines, plastic injection moulding machines, extrusion machines and printing equipment to produce world class products in compliance with international quality standards

3 GLOBAL PLAYERS December 2015 taken over by Delphi automotive Headquartered in UK, it is on of the world s largest automotive parts manufacturers 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

4 Head office facility Head Office Linbro Business Park - Site 22,000 m² - Offices 2,800 m² - Manufacturing 4,700 m² - Warehousing & Logistics 5,600 m²

5 Experience & Expertise Our local engineering staff have been involved in the tooling & plastic injection mould manufacturing in the Automotive industry for over 40 years Merged with HellermannTyton in 2015 HTSA Engineering is committed to continual improvement as a basic philosophy for achieving competitive and efficient manufacturing of world class products The ability to draw on HellermannTyton Group s world-renowned experience in the innovative design, development and manufacture of specialised plastic parts, gained over numerous years of successful operation around the globe

6 Tool Room Equipment State-of-the-Art Precision Engineering Equipment 2 x NC Spark Eroders 2 x CNC Spark Eroders 1 x Wire Cutter 3 x 3 Axis CNC Milling Machines 1x 4½ Axis CNC Milling Machine 2 x Surface Grinders 2 x CNC Lathes 2 x Heat Treatment Furnace 1 x Mechanical Saw 4 x Pedestal Drilling Machines 4 x Conventional Milling Machines 1 x Conventional Lathe 1 x Hardness Tester

7 Tooling Capability Small to Medium size tooling (up to 3 tons); 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 & CNC SYSTEM SOFTWARE: Creo Solidworks 2017 Mastercam 2018

8 CONDITION for industry to place orders on SA 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

9 Clustering - process flow Concept 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

10 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

11 Concept tooling type (Exactly how the tool will work) conceptual 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 com- ponents and cavities Fixture type: Pneumatic Mechanical Component sensing modules Trimming tools Mechanical/Hydraulic Orientation Cavities Post processing Machining Jigs Flow analysis Core pulling

12 SIMULATION Mould flow analysis Prototyping DFM

13 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

14 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

15 CLUSTER MANAENT 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

16 CLUSTER MANAENT

17 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

18 Visual Progress Reporting Example 1

19 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 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

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

21 SUCCESSES MBSA BRACKET TOOL LOCALISTION

22 Mercedes Benz (Cable Duct Inner RH & LH) New 1 st Tear supply to MBSA In-house mould design & Manufacture Collaboration UTP fastrack mould manufacture with advanced machined mould base Vehicle fitment for jig (Poke yoke) Limit switch activation on assembly of pin clamps & locks part in place Parts move down the shoot and are packaged accordingly All on one line assembly 22

23 SUCCESSES MBSA BRACKET TOOL LOCALISTION

24 TOOL 3D MEAUREMENT REPORT - UTP

25 PART 3D MEAUREMENT REPORT

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

27 NEXT STEPS Create Volume Capacity Pool knowledge Supplier Audits

28 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

29 NOW: Exporting moulds for group 1 st Project with HTG New Export moulds for HTG Production Poland 29

30 After 1 st project with HTG Over 40 projects quoted. 8 orders received since February 2018 further 7 PO s in progress Capacity planning being conducted to grow local capacity Money stays in the group Over R 300 million quoted in tooling 30

31 NOW: Exporting moulds for group in production Current project & Collaboration Clustering UTP 31

32 In progress With industry s support output has doubled 32

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34 Advanced machined Custom mould in parallel production 34

35 Fast track turnaround times 35

36 Group benefits by production in SA Growing capacity Clustering of local toolmakers finishing capabilities Designs to remain with HTSA Engineering Project Management to stay within HTSA Engineering Increase volume capacity Single face to the customer Supplier development & Upskilling Local incentives Local content kickbacks for OEMs Current annual South African tooling market worth R18 billion Only 12% produced locally WORKING TOGETHER WE CAN MAKE A DIFFERENCE!!! 36

37 ANY QUESTIONS? THANK YOU Chantelle Phillips Technical Projects Manager