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Development Process (3.2.3) Process Owner Presentation

Development Process (3.2.3) Process Owner Presentation. Cal-Comp USA 4-23-2012. Cal-Comp USA. Employees - 500 (San Diego, Indiana & Reynosa) AS9100, ISO/TS 16949 (Automotive), ISO 9001 & 13485 (Medical) Aerospace & Military Customers:. 2. Process Overview / Criteria. 3.

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Development Process (3.2.3) Process Owner Presentation

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  1. Development Process (3.2.3)Process Owner Presentation Cal-Comp USA 4-23-2012

  2. Cal-Comp USA • Employees - 500 (San Diego, Indiana & Reynosa) • AS9100, ISO/TS 16949 (Automotive), ISO 9001 & 13485 (Medical) • Aerospace & Military Customers: 2

  3. Process Overview / Criteria 3 3.2.3 Development Process • How does your organization design and develop new products or services? • How are advanced techniques such as Six Sigma, Design of Experiments, Design to Cost, Design for Manufacturability integrated into your operations? • How are customers and suppliers integrated into your development process? • How is the development process reviewed and improved?

  4. Our Key Practices Advanced Product Quality Planning-APQP (Design For Six Sigma-DFSS) • AS9100 7.0 Product Realization • 1.3.1 New Product Start-Up Process (APQP) • Development Process 3.2.3 • Production Preparation Process 3-P • Production Part Approval Process & FAI

  5. Things We Did Right Customer-focused Multi-disciplined Teams Developed at 1st Engagement With Champions • Program Manager • Manufacturing / Quality Engineer • Test Engineer • Value-Stream Manager • Production Planner • Procurement Specialist • Cell Leads • Key Supplier Representatives 5

  6. Things We Did Right Advanced Product Quality Planning Time-Line Concept Initiation / Approval LP- Lab Prototype (Proto) MP- Mfg. Prototype (Pilot) PP- Production Prototype (Launch) Program Approval Planning Planning Product Design & Dev. Process Design & Development Product & Process Validation Production Feedback Assessment & Corrective Action Product Design & Development Verification Process Design & Development Verification Feedback Assessment & Corrective Action Product & Process Validation Plan & Define Program

  7. Built Quality In With Core Tools 7

  8. DFMEA & PFMEA Benefits Design Failure Mode Effects Analysis - DFMEA • Design For Cost Reduction - DFCR Process Failure Mode Effects Analysis - PFMEA • Design For Manufacturability - DFM • Design For Assembly - DFA • Design For Test - DFT • Design For Serviceability – DFS • Mistake-proofing & Process Controls 8

  9. Multiple PDCA Experiments Concept Initiation / Approval Program Approval Prototype Pilot Launch Planning Planning Product Design & Dev. Process Design & Development Product & Process Validation Production Feedback Assessment & Corrective Action Product Design & Development Verification Process Design & Development Verification Feedback Assessment & Corrective Action Product & Process Validation Plan & Define Program

  10. Begin Lean With 3P At Prototype 3P - Production Preparation Process Note: Each color represents a different operator’s work cycle 10

  11. VSM From Raw Material to USAF 11

  12. Continual Improvement 12

  13. Things We Learned • Empowered Customer-focused Multi-disciplined Teams – Main Ingredient for Success • Product & Process Intimacy – Well Worth the Effort • Core Tools - Living Records of Our Very Best • 3P & APQP Work Hand-in-glove – Quality, Cost Reduction & Productivity Improved Together • Preventing Problems (Mistake-proofing) & Removing Waste in Advance – Smooth & Successful Launches • Improved DFX Capabilities – More Value-added Services for Our Customers • Ultra Effective Ramps – More Like Step-functions 13

  14. Questions Thank You Contact: Kenny Heifner kheifner@kinpogroup.com (858) 587-6960

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