RemPhos Manufacturing Danvers, MA March 15, 2012
Agenda Introduction to RPT Quality Control System Example Production Process RMA/Recent Process Improvements Conclusion
Company Goal: To be a partner in bringing the most innovative LED products to market with speed, quality, and cost effectiveness R&D & Small/Medium Production Capabilities: Danvers, Massachusetts, USA RemPhos has mechanical, electrical, optical, polymer, semiconductor and manufacturing engineers which provides OSRAM with a fast and effective way of researching, developing and prototyping DESIGN: CAD/CAM ANSYS thermal analysis Ray tracing and optical analysis Thermal and electrical testing PROTOTYPE: Plastics: Mold/die design, Compounding, Injection Molding, Extrusion, Thermoforming Metals: Mold/die design, 5 Axis CNC Mill, CNC Lathe, Metal forming, Extrusion, Foundry Electronics: Complete board layout, Circuit design, LED driver design, board production PRODUCTION: Class 100,000 Clean room with Die/Wire Bonders for LED COB Semi automated SMT line for mounting electrical components Semi automated assembly line (current output of ZELION lamp: 3200lamps/month) Capacity: <100,000pcs/yr (per product) High Volume Mass Production Capabilities: Xili, Shenzhen, China RemPhos has high volume production capabilities for 100,000+ pcs/yr in China. We currently have plastic/metal/ceramic/electrical partners in Asia, Mexico and Europe which we use to manufacture components for our current products MASS PRODUCTION: Fully automated SMT line Fully automated assembly Automated inspection Kaizen TQM Quality System ISO 9001 Compliance FDA Compliance, UL Certified, CSA Certified CAD design: OSRAM ITOS O ZELION Co-Extrusion (2) K&S 1484 Wire Bonders OSRAM ZELION LED Tube ANSYS Thermal Analysis 5 Axis CNC Mill SMT Line Medical Miniature Light Tools Ray Trace 2,100 ZELION Lamp shipment LED Driver PC BMW LED Upgrade
Pictures of RPT Danvers
Pictures of RPT China
Certifications RemPhos Danvers, MA OSRAM audited (2009,2010,2011,2012) UL audited (2012) CSA audited (2012) ISO 9001 compliance (working towards certification) RemPhos Shenzhen OSRAM audited (2010,2011,2012) UL audited (2011,2012) CE, TUV audited (2008,2009,2010,2011,2012) ISO 9001 certification (2008,2011)
Total Quality Approach
Total Quality Approach Formal Quality Training: Lean manufacturing engineering degree Trained in Kaizen, 5S, 5 why, root cause, Pareto, 8D Goal: Continuous Process Improvement!
Example Manufacturing Since 2008 Current capacity: flexible up to 2000units/week Typical team cell: 3-8 people
Manufacturing QC for Raw Material Manufacturing Incoming Inspection/Inventory Testing Analysis of Yields for Continuous Improvement
QC for Raw Material Manufacturing Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing QC for Raw Material Manufacturing
QC for Raw Material Manufacturing Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing Incoming Inspection/Inventory 7,000sqft
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing : 4,000sqft
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing Control Plans D/PFMEA Process Flow Inspection Reports
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing SMT
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing : MRB
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing Testing/Final Inspection Testing
QC for Raw Material Manufacturin g Incoming Inspection/Inv entory Testing Analysis of Yields for Continuous Improvement Manufacturing Analysis of Yields for Continuous Improvement
RMA/Recent Process Improvements Work closely with customer team in order to establish root cause of issue and quickly implement corrective action Example RMAs: Reverse Polarity Loose End Caps Damaged PP Diffusers
RMA/Recent Process Improvements Reverse Polarity
RMA/Recent Process Improvements Loose End Caps
RMA/Recent Process Improvements Damaged PP Diffusers
Conclusion Process Defined Continuous Improvement is our Goal Confident that Issues are being dealt with effectively Ready and excited for future production
Remote Phosphor is the future..