A Strategy to Improve Design Quality, Reduce Costs and Shorten Time to Market. 1 Copyright 2017 HCL Technologies Limited

Transcription

1 Presentation date: 24-Oct-2017 Presenter Name: Nitin Prayag Room name: Room 1 (Foyer Hall) Structured approach to excellence using DFMPro in NX A Strategy to Improve Design Quality, Reduce Costs and Shorten Time to Market 1 Copyright 2017 HCL Technologies Limited

2 Aerospace & Defense Automotive Consumer Electronics Industrial Mfg Medical Devices Telecom Service Provider Semiconductors Telecom Networking & Storage Office Automation ISV and online HCL Overview along with ERS Line of Business Snapshot HCL Enterprise $7.2B ENGINEERING and R&D SERVICES A $1.4 Bn+ UNIT UNDER HCL TECH IN REVENUE Top 3 Global Engineering Services Company 120,000 EMPLOYEES 32 COUNTRIES 40+ Years of Complex Engineering Experience 24,000+ Engineers 55 of Top 100 Global R&D Companies as Customers 100+ Client Development Centers and 110+ Customer - Specific Labs 1,250+ Patents Filed for Customers $25M+ Worth Investments in Laboratory Facilities FPGA, ASIC and SOC Design Embedded Systems Hardware & System Design Mechanical Design GeometricPLM Software Product and Platform Engineering Product QA and V&V 2 Copyright 2017 HCL Technologies Limited

3 References from Around the World Indicate the Huge Cost and Effort Impact Associated with Engineering Change Orders Cost of change in US $ (As an example in automotive industry the average value of x = 4K - 6K per change) 100 x The typical cost of design change ECOs consume one third to one half of engineering capacity Soderberg, L.G., Facing up to the engineering Gap. McKinsey Quarterly ECOs represent 20 to 50% of tool costs (around 100M USD in large projects) Lincke, W. Simultaneous Engineering Approximately 80 x SHIFT THE MOUNTAIN 30% of all work effort was due to engineering changes Fricke et al 10 x The typical number of design changes A study of over 2,000 ECOs created over the course of three months at an industrial equipment manufacturing company has shown that DFX Issues contribute to around 70% of engineering change orders. These DFX issues fall in the preventable category Average number of ECOs in aerospace could be around per program per year - In total, the number of ECOs could exceed 5000 per year x Basic Idea, Concept, Evaluation Phase Detailed design Release design to manufacturing Build design Test design The factory begins to fabricate Time Current design in production Approximately 4-5% of the Engineering Change Orders are linked to non-adherence of Design/Manufacturing/ Assembly rules Average ECO cost could be as high as USD across the development lifecycle 3 Copyright 2017 HCL Technologies Limited

4 To Consider all Aspects of Product Designs, Designers should Take the Holistic Approach Quality Is uniform wall thickness maintained? Is the required clearance maintained between the parts? Assembly Safety Assembly Service Environment Can this contact area lead to corrosion because of incompatible materials? Reliability Is the correct draft angle applied? Manufacturing Is the hole aligned properly? Disassembly Commonality DFX Procurement Manufacture Is the thread engagement sufficient for the joint? Manufacturing Assembly Is the fastener accessible for serviceability? Reuse Environment Reliability Costing Can this fillet radius be achieved through the casting process? Service Design For excellence (DFX) consists of methods, guidelines, standards and checks for creating better products focused on providing benefits in multiple stages of the product lifecycle 4 Copyright 2017 HCL Technologies Limited

5 DFMPro Enables Organizations to Take Frontload Decisions DFMPro for NX Solution Manufacturability and Cost drivers Create Input DFMPro NX Output Optimized design Ready For Manufacturing Design Modify 3D Model Manufacturability report Elements of cost Supplier Capability Competency Global Best practices Knowledge Capture Sourcing Manufacturing Service Knowledge Database 5 Copyright 2017 HCL Technologies Limited

6 and Comes with Built in Checks for Standard Manufacturing Processes Injection Molding Machining Sheet Metal Assembly Casting Additive Manufacturing 6 Copyright 2017 HCL Technologies Limited

7 Fastener Accessibility Producibility Serviceability Rate of production Ease of service To ensure ease of assembly and maintenance, clear access for fastening tool has to be provided 7 Copyright 2017 HCL Technologies Limited

8 Fastener Clearance Quality Best Practices Radial Clearance Clearance beyond bolt projection Screw Insert Boss To ensure ease of assembly and error-free operation, sufficient axial and radial clearance for a fastener should be provided Axial Clearance for a Screw 8 Copyright 2017 HCL Technologies Limited

9 Sharp Internal Corner Producibility Cost Quality Rate of Production Tooling Cost Sharp inside corners require expensive and machining methods like EDM 9 Copyright 2017 HCL Technologies Limited

10 Deep Radiused Corners Quality Cost Best Practices Tooling Cost Deep radiused corners require longer end mills prone to breakage, chatter and requiring longer machining times. 10 Copyright 2017 HCL Technologies Limited

11 Preferred Holes Size Producibility Rate of Production Standard and uniform drill sizes are preferred to avoid extra tooling and setup time. Ultimately it will reduce cost of manufacturing and reduces cycle time. 11 Copyright 2017 HCL Technologies Limited

12 Knife Edge Quality Safety Knife/sharp edges should be avoided for ensuring safety and promote ease of handling, eliminating additional operations cost and preventing fatigue failures 12 Copyright 2017 HCL Technologies Limited

13 Three Steps for Successful DFX Deployment for Your Organization Define Key priorities for your organization- Time to market, reduce Engineering Changes, improve quality, improve Engineering productivity Set up a DFX organization and identify DFX champion Identify key rules for business benefits Identified key location for deployment Configure OOTB DFMPro+Checkmate for validation based on company standards Feedback from various stakeholders on downstream DFX requirements Convert DFX requirements to rules for development in DFMPro Roll-out, installation, training, customization Weekly DFX meetings to track the usage and address key issues ENTERPRISE DEPLOYMENT Deploy DFMPro+Checkmate for all target users All locations Standard and custom rules covering organizational knowledge base Set up a process to ensure continuous knowledge capture & implementation of specific rules Continuous improvement by building new rules to avoid occurring Engineering changes and quality issues Monthly DFX meeting to track the usage, benefits and new improvements required. Step 1 - Define Priorities for your Company Step 2 - Pilot deployment Step 3 - REALIZATION OF BENEFITS 13 Copyright 2017 HCL Technologies Limited

14 Closed Loop Quality Feedback Implementation to Avoid Reoccurrence of Changes Related to Quality and Design Designer Create Modify Supplier Capability Global Best practices Competency Knowledge database Continues improvement 14 Copyright 2017 HCL Technologies Limited

15 NX Design Validation DFMPro for NX Check-Mate NX Design Validation DFMPro & Check-Mate NX Unified Design Validation Framework Features Geometry Drawings, Sketches Modeling Standards PMI checks File Structure Modeling practices Customer specific checks Drilling Manufacturability Milling Turning Casting Injection Molding Assembly Standardization Standard tools Tolerances Standard components Customer Mfg standards Customer Specific rules 15 Copyright 2017 HCL Technologies Limited

16 Results in Teamcenter How do DFMPro+Check-Mate results work with Teamcenter? DFMPro+Check-Mate can use the Validation Manager application within Teamcenter to store and manage its results DFMPro+Check-Mate results for a part are stored in a Validation Master Form under the item revision Each check (or profile) is marked as out-of-date or pass/fail 16 Copyright 2017 HCL Technologies Limited

17 Benefits from Implementing DFX Solution Hard Savings Standardization across different R&D locations 1. Features 2. Drawings 3. Materials 4. Design Procedures and processes Soft Savings Overall improvement in Product quality and capability of the tool to predict and arrest all design related quality issues for NPD Cost savings from reduced number of ECO s Savings from improvement in Engineering productivity Reduced Tooling costs and warranty costs Improved First time right time to market due to savings in reduced EC s Capture knowledge within organization including supplier s capability Time savings from collaboration between teams and suppliers 17 Copyright 2017 HCL Technologies Limited

18 Thank You For queries 18 Copyright 2017 HCL Technologies Limited

19 Motivation Key focus Description Customer Impact Reduced Engineering Changes Design Quality Improvement Reduced engineering rework, more time and focus for core R&D activities Reduction in turn-backs from downstream to design Help to meet aggressive schedules in demanding environment with improved efficiency Reduction in downtime/delays in downstream functions. Overall reduction in rework costs Improving Time to Market Ship products faster to market compared to competition Savings in opportunity cost Reducing Product Costs Improve standardization and manufacturing time thus reducing the cost of the product Improved control on effective pricing/higher profits due to lower product costs Knowledge Capture Improved mechanism to capture knowledge in a system Capture knowledge from Ageing workforce and mitigate risk, improve competency of new engineers 19 Copyright 2017 HCL Technologies Limited