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Production Preparation Process

Production Preparation Process. The SMS Technologies Quality Management System includes: ISO 9001, AS9100, ISO 13485, and ISO/TS 16949 They All Include Product Realization Advanced Product Quality Planning Production Preparation Process Production Part Approval process.

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Production Preparation Process

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  1. Production Preparation Process • The SMS Technologies Quality Management System includes: • ISO 9001, AS9100, ISO 13485, and ISO/TS 16949 • They All Include Product Realization • Advanced Product Quality Planning • Production Preparation Process • Production Part Approval process

  2. APQP, Flow Charting, Process FMEA, Control Plan, 3-P & PPAP • APQP = Advanced Product Quality Planning • Build 1st-time Quality into the Production Process • FMEA = Failure Mode Effects Analysis • Minimize Risk (DFM, DFT & Mistake-Proofing) • 3-P = Production Preparation Process • Build to Customer Demand Beginning at Launch • PPAP = Production Part Approval Process

  3. PRODUCT QUALITY PLANNING TIMING CHART CONCEPT INITIATION/ APPROVAL PROGRAM APPROVAL PROTOTYPE PILOT LAUNCH PLANNING PLANNING PRODUCT DESIGN AND DEV. PROCESS DESIGN AND DEVELOPMENT PRODUCT & PROCESS VALIDATION PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION Planning INPUTS | Planning OUTPUTS Product Design & Dev. INPUTS | Product Design & Dev. OUTPUTS Process Design & Dev. INPUTS | Process Design & Dev. OUTPUTS Product & Process Validation INPUTS | Product & Process Validation OUTPUTS Production INPUTS | Production OUTPUTS

  4. SEI Process Flow Diagram

  5. Process Failure Mode Effects Analysis

  6. Proto-type, Pre-launch & Production Control Plans

  7. Operator Work Instructions Work Instructions with applicable drawings, etc. are developed for each material transformation:

  8. The Key Linkages for Customer Special Characteristics Process Flow Chart FMEAs Control Plans Operator Instructions PPAP Core Tools Applications

  9. Defining & Balancing The Cell

  10. Calculating Takt Time Total Shift Hours = 8 X 60 min. X 60 sec. = 28,800 seconds -2 - 15-minute breaks X 30 min. X 60 sec. = 1,800 seconds -Start-up & Shut-down = 15 min. X 60 sec. = 900 seconds Available Work Time = 26,100 seconds Takt Time = Available Work Time / Customer Demand (units) TAKT TIME = 26,100 Seconds / 50 Units = 522 Seconds TAKT TIME = 522 Seconds / 60 = 8.7 Minutes Build a cell that will produce one unit every 8.7 minutes!

  11. Defining & Balancing The Cell

  12. Defining & Balancing The Cell Until learning curves been achieved, work portions are allowed to vary slightly around the takt time until conducting further studies:

  13. Preliminary SEI Cell Floor Layout

  14. Varying The Cell Volume Scaling Volume by Adding Shifts

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