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
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
PRODUCT QUALITY PLANNING TIMING CHART
CONCEPT
INITIATION/ PROGRAM
APPROVAL APPROVAL
PROTOTYPE
PILOT
PLANNING
LAUNCH
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
SEI Process Flow Diagram
Process
Flow Chart
Start
Input or
Output
Blocks
Instructional
Blocks
Decision
Blocks
Yes
No
Subroutine
Blocks
(i.e. Rework)
Input or
Output
Blocks
End
Process Failure Mode Effects Analysis
Proto-type, Pre-launch &
Production Control Plans
Operator Work Instructions
Work Instructions with applicable drawings, etc. are
developed for each material transformation:
The Key Linkages for Customer
Special Characteristics
Process Flow Chart
FMEAs
Control Plans
Operator Instructions
PPAP
Core Tools Applications
Defining & Balancing The Cell
CCA-25000-1101
Epoxy
magnet to
Slide switch
1.0 min
RTV Reed
Switch
1.75 min
FIFO
??
Install slide
switch
1.75 min
CCA-25000-1201
CCA-25000-1301
Install
Radome
Cover
6.0
X-ray BGA &
QFN
Solder 5
wires
7.min
X-ray BGA &
QFN
Depanel 4 up
RF Func test
aray
Apply Epoxy
5.5 min
.3 min
Depanel 4 up Hand Solder Program and
array
J4, J7
func test
.3 min
2.0 min
8.16 min
Interim insp
1.0 min
RTV 1st
Cable
5.0 min
GPS Chassis Instal RF Bd
test
6
6.0 min
.0 min
Scan GPS and
TXC SNs into
data base
1.0 min
Install Blade
Antenna
.5 min
RTV 2nd
Cable
5 min
FIFO
42
Final Insp
4.3 min
VSWR Test
3.0 min
Solder 2
standoffs and 3
resistors to flex
1.5 min
Install Batt
contacts
3.0 min
FIFO
??
Insp
.5 min
Insp
.5 min
Insp Contacts
.5 min
Reed Switch
Install Rotory Install Rotory
insp
Switch
switch knob
.5 min
1.25 min
1.25 min
(sample)
SEI
Assemble
5.0 min
Hand solder
Cable
2.5 min
Prep Neg Bat Prep Pos Bat
Terminal
terminal
1.0 min
1.0 min
FIFO
42
Reed switch
Test
.5 min
Depanel 25
up PCBA
.3 min
Trim
fixture
for
Neg
Term
Epoxy Ant
reed switch
2.75 min
FIFO
42
Install Ant
matching
PCBA
1.2 min
Solder ant pin Install Remote
Chassis Insp
to PCBA
Adaptor Assy
1.0 min
.5 min
5.0 min
Transport
1 day
Final Insp
Combo RF/
GPS test
4.3 min
Install
Matching
Cable-RF Bd
.5 min
Solder 3 ultra
caps to flex
cable
7.5min
500 units/wk
100 units per
day
50 units per
shift
Install shield
covers
3.0 min
Full Func
Test
2.0 min
Insp Ultra
Cap assy
.5 min
GPS/RF
PCBAs in
chassis insp
1.0 min
Solder Reed
Switch
2.0 min
Battery Cover
Interim Insp
install
1.0 min
1.0
RTV Flex Cable
to Cover
2.2 min
FIFO
??
Top Cover
Assy
4.0 min
Insp
.5 min
Shipping
Staging
Leak test
2.0 min
Seal Screw
.5 min
Final Insp
and Docs
5.0 min
Pack out
.33 min
Calculating Takt Time
Total Shift Hours = 8 X 60 min. X 60 sec. = 28,800
-2 - 15-minute breaks X 30 min. X 60 sec. = 1,800
-Start-up & Shut-down = 15 min. X 60 sec. = 900
Available Work Time = 26,100
seconds
seconds
seconds
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!
Defining & Balancing The Cell
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
Ultra Cap sub assy
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
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
Pack out
.33 min
Shipping
Staging
Defining & Balancing The Cell
Until learning curves been achieved, work
portions are allowed to vary slightly around the
takt time until conducting further studies:
10
9
8
7
6
5
4
3
2
1
Operation 1
Min.
7.50
2
9.00
3
8.25
4
7.50
5
8.50
6
7.30
7
7.70
8
8.60
9
9.00
10
8.00
11
8.00
12
8.00
13
9.00
14
9.00
15
7.83
FLOW
TD
TD
5 ft
Blade Ant VSWR and
battery cover
T
T
4 ft
Rotory/GPS
Wiring
4 ft
GPS Test/RF
Install
T
TD
4 ft
Bd insp - GPS/
Radome install
4 ft
Ant matching/
Remote adp assy
S
M
Depanel
Arbor
S
4 ft
Batt terminal Prep
and assy
O
4 ft
Remote Conn
assy/insp/cover
install
S
6 ft
Debug Station
10 ft
RF Bd test/final assy
S
TD
M
6 ft
Insp/Combo test
M
T
T
10 ft
GPS Bd test/final assy
T
S
M
T
1201
7.88 min
TD
T
To Shipping
TD
TD
O
1301
1101
3 ft
RTV Cables
TD
4 ft
Final TEST and
pack out
4 ft
Initial Chassis
assy
Hepco
5 ft
Ultra Cap sub assy
O
3ft
Top cover,
Leak test and
Final assy
S
SSIS
CHA
MAIN COVER
Preliminary SEI Cell Floor Layout
TD
S
M
O
TEST
TORQUE DRIVER
SOLDERING STATION
MANTIS
OVEN
Varying The Cell Volume
Scaling Volume by Adding Shifts
# of Shifts Daily # Weekly # Monthly #
1
50
250
1000
2
100
500
2000
3
150
750
3000