Discipline / Competence / Innovation / Transcendence / Sincerity / Harmony

End-to-End Electronic Manufacturing
Services: Commercial, Industrial, Defense,
Automotive and Medical Industries

Employees ~ 1200 (San Diego - CCSD,
Indiana - CCIN & Reynosa - CCMX)
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Aerospace & Military Customers:
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Confidential
 How does your organization contribute to the
immediate success of customer startup operations
including first article and early production efforts?
 How are processes like Advanced Product Quality
Planning “APQP” and Production Preparation
Process “3P” used to pro-actively ensure value for
customers?
 How are customer’s needs for reduced lead time
and high levels of initial quality considered in the
startup process?
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Confidential
 AS9100 7.0 Product Realization
 1.3.1 New Product Start-Up Process
[Advanced Product Quality Planning (APQP)]
 Prototype Program (Development Process)
 Production Preparation Process 3-P
 Production Part Approval Process & FAI
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“Zero Defects Mentality”
QS 9000 CCIN 1999
TS 16949 CCIN 2004
TS 16949 CCSD 2005
TS 16949 CCMX 2005
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O
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Partnership
Development
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O
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O
O
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Production
Manufacturing
I
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• Advanced Product Quality Planning (APQP)
– Start in “Advance”
– Customer & Supplier Involvement Early
• Partnering to achieve product & process intimacy
– Design Quality Into Product & Processes
• APQP = Design For Six Sigma (DFSS) Zero Defects
• Process Flows – FMEAs – Control Plans – WIs
– Production Preparation Process (3P)
• Integral to APQP & DFSS – DFL (Design For Lean)
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Concept
Initiation /
Approval
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Dev.
Process Design & Development
Product & Process Validation
Production
Feedback Assessment & Corrective Action
Plan &
Define
Program
Product Design
& Development
Verification
Process Design
& Development
Verification
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Product &
Process
Validation
Feedback
Assessment &
Corrective
Action
Confidential
Process Failure Mode Effects Analysis – PFMEA
- Design For Six Sigma in Every Way – DFX Design For Manufacturability - DFM
 Design For Assembly - DFA
 Design For Test - DFT
 Design For Serviceability – DFS
 Mistake-proofing (Poka-yoke) & Process Controls

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Confidential
Design Records,
DFMEAs and
Special / Key
Product
Characteristics
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Confidential
Engineers Qualify Master Trainers Using T3 Qualification
Master Trainers Deliver
Competency-based Training
Using 4E Methodology
1.Example (Demonstration)
2.Experience (Effectiveness)
3.Efficiency (Takt Rate)
4.Evaluation (Qualification)
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Confidential
Members of AME (the Association for
Manufacturing Excellence) 2004 - 2007
Members of SEA
(the Supplier
Excellence Alliance)
2008 - 2013
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Confidential
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!
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Confidential
CCA-25000-1101
Trim
fixture
Depanel 25
up PCBA
.3 min
Pizza
cutter
Epoxy
magnet to
Slide switch
1.0 min
R/I to do
Reed switch
Test
.5 min
RTV 1st
Cable
5.0 min
RTV 2nd
Cable
5 min
RTV Reed
Switch
1.75 min
FIFO
4
Reed Switch
Install Rotory Install Rotory
alignment
Switch
switch knob
and insp
1.25 min
1.25 min
.5 min
RTV Cables
X-ray BGA &
QFN
CCA-25000-1301
RF
Depanel 4 up
RF Func test
aray
5.5 min
.3 min
Pizza
and
Dremmel
tool
CCA-25000-1201
GPS
Depanel 4 up
array
.3 min
Apply Epoxy
1.0 min
Solder 5
wires
7.min
Interim insp
1.0 min
Rotory/GPS Wiring
FIFO
4
Hand Solder
J4, J7
2.0 min
Func test
4.4 min
Scan GPS and
TXC SNs into
data base
1.0 min
GPS Chassis Install RF Bd
test
Part 1
4.0 min
4.0
GPS Test/RF Install
Instal RF Bd
Part 2
2.0 min
Final Insp
4.3 min
VSWR Test
3.0 min
Combo RF/
GPS test
4.3 min
Install shield
covers
2.0 min
500 units/wk
100 units per
day
50 units per
shift
Ant matching/Remote adp assy
Install
Matching
Cable-RF Bd
.5 min
Solder 3 ultra
caps to flex
cable
7.5min
GPS/RF
PCBAs and
chassis insp
1.0 min
Solder Reed
Switch
2.0 min
Transport
1 day
Bd insp - GPS/Radome
install
Full Func
Test
2.0 min
Battery Cover
install
1.0
Interim Insp
1.0 min
Top Cover
Assy
4.0 min
Insp Ultra
Cap assy
.5 min
RTV Flex Cable
to Cover
2.2 min
FIFO
14
Leak test
2.0 min
Seal Screw
.5 min
Final Insp
and Docs
5.0 min
Pack out
.33 min
Shipping
Staging
Final op pack out
Top cover and Final assy
Blade Ant VSWR and final test
Solder 2
standoffs and 3
resistors to flex
1.5 min
Solder ant pin Install Remote
Chassis Insp
to PCBA
Adaptor Assy
1.0 min
.5 min
3.0 min
Remote Conn assy/insp/cover install
Insp/Combo test
Install Blade
Antenna
.5 min
Install Ant
matching
PCBA
1.2 min
SEI
Final Insp
.5 min
RF Bd test/final assy
GPS Bd test/final assy
Install
Radome
Cover
6.0
FIFO
4
Epoxy Ant
reed switch
2.75 min
Batt terminal Prep and assy
Initial Chassis assy
Pizza
cutter
Install Batt
contacts
3.0 min
Insp
.5 min
Insp
P/O Chassis
insp
Insp Contacts
.5 min
Install slide
switch
1.75 min
FIFO
14
Hand solder
Cable
2.5 min
Prep Neg Bat Prep Pos Bat
Terminal
terminal
1.0 min
1.0 min
Trim
fixture
Assemble
Remote Conn
Adaptor
5.0 min
Insp
.5 min
Ultra Cap sub assy
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Confidential
TD
T
T
4 ft
GPS Test/RF
Install
4 ft
Rotory/GPS
Wiring
T
4 ft
Bd insp - GPS/
Radome install
S
M
Depanel
4 ft
Ant matching/
Remote adp assy
O
10 ft
RF Bd test/final assy
TD
4 ft
Remote Conn
assy/insp/cover
install
S
M
S
6 ft
Insp/Combo test
6 ft
Debug Station
M
T
T
10 ft
GPS Bd test/final assy
T
S
M
T
TD
1201
T
To Shipping
TD
1301
1101
TD
5 ft
Blade Ant VSWR and
battery cover
S
7.88 min
4 ft
Final TEST and
pack out
TD
TD
TD
O
4 ft
Batt terminal Prep
and assy
Hepco
FLOW
Arbor
SSIS
CHA
MAIN COVER
5 ft
Ultra Cap sub assy
O
4 ft
Initial Chassis
assy
3 ft
RTV Cables
3ft
Top cover,
Leak test and
Final assy
S
TD
S
M
O
TEST
TORQUE DRIVER
SOLDERING STATION
MANTIS
OVEN
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Confidential
Scaling Volume by Adding Shifts
# of Shifts Daily # Weekly # Monthly #
1
50
250
1000
2
100
500
2000
3
150
750
3000
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Confidential
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 / 67 Units = 390 Seconds
TAKT TIME = 390 Seconds / 60 = 6.5 Minutes
Rebalance the cell to produce one unit every 6.5 minutes!
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Confidential
Epoxy magnet to
Slide switch
1.0 min
FIFO
55
Trim
fixture
CCA-25000-1101
Test Reed
Switch On/Off
with Ohmeter
0.25 min
Install Ant
Install Batt contacts
Assemble Remote
matching PCBA
and Battery label
Conn Adaptor
& solder pin
4.0 min
4.0 min
2.0 min
6 hours
SEI
Paint touch up
1.0 min
RTV 2 RF Cable
assemblies
3.83 min
Install slide switch
1.0 min
Install Rotary Switch
& Black knob
1.33 min
RTV Reed
Switch
1.17 min
FIFO
19
2 hours
2ND ASSY 1
Slide switch & RTV RF Cables
Combo RF/GPS
test
4.25 min
Install RF bd
shield covers
0.33 min
Install Blade
Antenna
.5 min
VSWR
Test
3.5 min
FIFO
55
6 hours
2ND ASSY 3
Battery contacts and Ant PCBA
2ND ASSY 2
Rotary switch. Reed switch w/RTV and Epoxy
Ant pin & Reed switch
Install GPS bd Test Reed Switch
shield cover On/Off with Ohmeter
0.17 min
0.5 min
COMBO TEST (FCT 3 AND FCT4 ON RF BD)
Combo test and shield covers
Epoxy Ant pin
& reed switch
1.67 min
Install
Radome
1.0
Solder Reed Switch
& Install GPS bd
4.0 min
Plug in J5
and J4
0.33 min
SN ASSOCIATION
GPS bd & Radome install
Plug in Ant Matching O-ring for batt cover RTV Ultracap Flex
Cable-RF Bd
& install screws
to Top Cover
0.17 min
2.0 min
1.75 min
FCT 2
Blade Ant, VSWR and Batt cover
FIFO
19
INTERIM INSP 1
Remote int. adaptor
Test Reed switch
Solder 5 wires
for sticking
6.0 min
0.42 min
Rotary switch Install RF Bd, solder 2
test FCT1
batt wires & plug in J4
1.17 min
4.5 min
INTERIM INSP 2
Rotary switch/GPS Wiring
FCT 1
Rotary switch Test & RF bd Install
Top Cover w/4 screws, Torque Batt.
O-ring, EMI shielding
cover
3.0 min
0.3 min
Leak test
1.17 min
INTERIM INSP 3 & FCT 3
Top cover, Leak test & Final assy
Remove
battery cover
0.33 min
Full Func
Test
2.5 min
Install Remote
Adaptor Assy
2.5 min
Install Seal
Screw
0.33 min
500 units/wk
100 units per
day
50 units per
shift
Transport
1 day
Install batt cover, Final
Insp, shipping box & Docs
1.0 min
Shipping
Staging
FCT 4 & FINAL INSPECTION
Final Test and pack out
Ultracap sub-assy
6.0min
NO SCANPOINT
Ultra Cap sub assy
Updated: 6-15-09
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Confidential
ing
hipp
To S
FCT4 & FINAL INSP
Final Test and pack
out
COMBO TEST
Combo test & shield covers
SN ASSOCIATION
GPS Bd & Radome install
INTERIM INSP 2
Rotary switch/GPS Wiring
2ND ASSY 3
Batt contacts & Ant PCBA
2ND ASSY 2
Rot sw, Reed sw w/RTV &
Epoxy Ant pin & Reed sw
S
4
S
INTERIM INSP 1
Ant matching/
Remote adp assy
M
3
Hepco
S
2
S
M
S
FCT1
Rotary sw test & RF
bd install
2ND ASSY 1
RTV RF Cables &
Slide switch
1
FCT2
Blade Ant, VSWR and
battery cover
CH
AS
SI
S
S
IN
MA
INTERIM INSP 3 & FCT3
Top cover, Leak test and
Final assy
7
9
11
Ultra Cap sub assy
ER
OV
6
YC
ER
TT
BA
5
1101
01
01
13
12
8
12
10
R
VE
CO
SOLDERING STATION
MANTIS
Updated: 6-15-09
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Confidential
Scaling Volume by Reallocating Operators:
# of People
15
# of Portions 1 each
# Per Shift
50
5
3 each
16
3
5 each
10
Balancing to 12 instead of 15:
# of People
12
# of Portions 1 each
# Per Shift
67
6
2 each
33
4
3 each
22
20
3
4 each
16
2
6 each
11
1
12 each
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Confidential
21
Confidential
RAW
LONG-LEAD
ALUMINUM
ITEMS
SUPPLIER
ADC
CCSD
SEI
PRODUCTION
CONTROL
PRODUCTION
CONTROL
SALES ORDER
BANK
CUSTOMER
LOCATIONS
USAF
SHIPPED AS
SHIPPED AS
WEEKLY
AS NEEDED
SHIPPED AS
SHIPPED AS
1x DAY
1x DAY
CUSTOMER
LOCATIONS
ADC
CCSD
LOCATIONS
CUSTOMER
CUSTOMER
LOCATIONS
100 Day
100 Day
100 Day
SEI
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FINISHED
GOODS
Confidential
Concept
Initiation /
Approval
Program
Approval
Prototype
Pilot
Launch
ACT
PLAN
Planning
ACT
PLAN
CHECK
DO
Planning
CHECK
DO
Product Design & Dev.
ACT
PLAN
Process Design & Development
CHECK
DO
Product & Process Validation
Production
Feedback Assessment & Corrective Action
Plan &
Define
Program
Product Design
& Development
Verification
Process Design
& Development
Verification
23
Product &
Process
Validation
Feedback
Assessment &
Corrective
Action
Confidential
24
Confidential
Contact: Kenny Heifner
kheifner@smstech.com
(858) 587-6960
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Confidential