Simultaneous product and production development at Philips Turnhout

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1 Simultaneous product and production development at Philips Turnhout Hans Van Reusel - Philips Innovation Services Gert Janssen - HID product development manager

2 Accelerate your innovation Introducing Philips Innovation Services 2

3 Accelerate your innovation Equipment Development Industry Consulting Philips Innovation Services Concept Creation Support Product & Process Development Prototyping & Small Series Industrialization A service provider Quality & Reliability Sustainability, Safety & Health 3

4 Industrialization The link between Product Development and Production PRODUCT DEVELOPMENT Philips Innovation Services GTDM PRODUCTION 11/11/2013

5 Industrialization Activities and Competences Concept Specification Engineering Realization Service Product codevelopment Research Feasibility studies Concept creation Consulting Lean solutions Industrial Setup Manufacturing process development Design for Six Sigma Design for manufacturing Prototyping studies Concept freeze Mechanical, electrical and software design FEM analysis System integration Project management CE -Safety Ergonomics Global sourcing Assembly Start & ramp up Training Repeats Product range & capacity extension Productivity improvement Spare parts management Relocation

6 A track record of successful innovations Ideation & Innovation Planning Value Proposition Creation & Advanced Development Product & Services Development & Market Introduction Life Cycle Management Innovation Strategy Landscaping & Ideation Innovation Planning Programming Value Proposition Creation Technology & Function Creation Architecture & Platform Creation Product Development & Industrialization Market Introduction Feedback Maintenance End Of Life aligning industrialization with the Philips Lighting Idea to Market process (I2M)

7 Why product & manufacturing specialists should cooperate early on Product & process/manufacturing specialists together can find the optimum balance between product performance and manufacturability: Materials selection => processability Component design => production cost, ease of assembly Testing strategy => how to monitor/control product quality Early cooperation allows to fix problems faster and at lower cost 7

8 Design for Six Sigma (DfSS) embedded in PRI Design-for-Six-Sigma is: Right-Design-Right a structured method (D-I-D-O-V), to design proactively products and processes, of a predictable robust quality, based on quantified specifications, agreed with customers and suppliers. DfSS: a proactive method to design new products Define Identify Design Optimize Verify Measure Explore Describe Improve Control Monitor MEDIC: a re-active method to improve existing products 8

9 The different stages of DFSS (DIDOV) Voice of the Customer Needs System Level Requirements Cp Optimize & Verify System Level CTQs.. Subsystem Level Requirements Cp Subsystem Level CTQs.. Subassembly Level Requirements Cp Subassembly CTQs.. Define & Identify Component Critical to Quality Requirements Cp Component CTQ Specs. Design Mfg. Process Requirements Cp Mfg. Process CTQ Specs 9

10 Example Salt dosing new gen CDM

11 GEN4. Complexity : Accent->Ultimo 1. Salt 2. Feedthrough 3. connection 4. Seal 5. ZUP 6. Antenna 11

12 Case salt doser (Bart L) Breakthroughs needed Size Accuracy.

13 Industrialization MPCP: how? Define assignment Projectname MPCP Project Leader Identify critical Ulimo processes Ward Cottaar Evaluate multiple alternatives Project Plan: ECP/MPCP PCP SPD completion score MS-3 MS-2: MS-2 Create risk overviewmrt '09 MS-1: MS-1 mrt '09 MS0: MS0 t '08 mrt '10 MS2: MS1 jan '09 mrt '10 MS3: MS2 jul '10 MS2+ MS3 jun'11 Make proces descriptions Set-up Enter data proces in yellow fields flow only! Set-up Qmap / critical parameter overview Processes SPD step finished? (yes = "") Transl. customer wishes to key end product spec's SPD Preparation Phase SPD Step 1-3 Describe and identify Colour process steps: g(reen), o(range), r(ed) Verify on final production set-up Define final settings Alternative processes evaluated Risk Maturity Grid filled-in from MS1 to 2 SPD Step 7-8 Perform verification on mechanised equipment Q-map from MS -1 to 0 Parameter List SPD Step 4-6 Analyse and DoE's done Optimise Tolerance analysis done from MS2 to 3 SPD Step 9-10 Assess control Processes Verify parameter Process Control Verify %R&R Short term Control charts Long-term OCAP's settings FMEA plan finished Cpk available Cpk available critical parameters mercury dosing 12% % salt dosing 8% % plug dosing Define proces windows 5.60% % SPD Step 7-8 Perform verification on test equipment (PMO) Cmk at required level Parameters future control plan identified Required %R&R achieved Risk Maturity Grid up-todate mercury dosing o for LTD 95% salt dosing o 90% plug dosing r ongoing 80% 75% ongoing Measure performance MPCP philosophy ingrained in our organization for over 10yrs Extensive testing (DoE) of identified Monitor long term performance MPCP philosophy crosses boundaries product development machine creation Validate chosen solution Define production- & test- equipment Update risk overview Green and Black belt training programs support this way of working Build tolerance analysis SPD report SPD step finished? (yes = "")

14 from MS -1 to 0 Industrialization MPCP: example 1-3 SPD Step 7-8 Step 7 SPD SPD Step 4 Preparation -6 SPD Phase SPD Step 1-3 SPD Preparation Phase SPDStep Step7 Describe 4-6Step SPD - 8 Step 9-10 SPD - 8SPD and identify Perform verification on test equipment (PMO) Analyse and Optimise Processes Transl.identify customer Colour process Alternative Risk Maturity and Q-map Parameter DoE's done Tolerance Cmk at verification Parameters Required on Risktest SPDequipment (PMO) Describe and Analyse Perform Perform verification Assess control wishes to key end steps: g(reen), processeson Grid mechanised filled-in Listequipment analysis required level future control %R&R Maturity report product spec's o(range), r(ed) evaluated done plan achieved Grid up-to- Optimise identified date Q-map DoE's done Transl. Tolerance customer Colour Cmkatprocess Required Risk Maturity Risk OCAP's SPD mercury dosing o for LTDParameters Alternative 95% Processes parameterparameter Process Verify %R&R Short term Control Long-term saltverify dosing o Control charts 90% plug dosing ongoing 80% 75% %R&R ongoing wishes to key end steps:level g(reen), processes Grid filled-in List r analysis required future control Maturity report settings FMEA plan finished Cpk available Cpk available productdone spec's o(range), r(ed) plan evaluatedachieved Grid up-to- 12% % identified mercury dosing for LTD o date 95% SPD step finished? (yes = "") salt dosing plug dosing 8% 5.60% o from MS1 to 2 SPD Step 775% -8 80% Perform verification on mechanised equipment Processes Verify parameter settings mercury dosing salt dosing plug dosing Process FMEA Control Verify %R&R plan finished 12% 8% 5.60% from MS2 to 3 SPD Step 9-10 Assess control Short term Cpk Control charts Long-term available Cpk ongoing r % 90% 60% 1.64 ongoing OCAP's available 80% 75% 60% SPD step finished? (yes = "") Bulk One by one 200µm 800µm Probability 5 Probability: 1: failure unlikely, <1 p pm 2: relatively few failures, 10 ppm 3: o ccasional faiures, 1 in : frequen t failures, > 1 in 20 5: failure inevitable, > 1 in 3 OK 4 24, 25 NOK but will be fixed 3 3, 6, 10, 2, 5, 13, 9, 12, 23, 26, 27, Showstopper , 22, 28 15, 32 1, Severity (customer effect): 1: n o no ticable effect 2: aesthetic failure, defect noticed by d iscriminating customers 3: item o perable but co mfort/convenience is compromised. Most customers dissatisfied. 4: item in op erable. Customer dissatisfied. 5: un safe op eration/ non-compliance with regulation Severity (manufacturing/ assembly effect): 1: n o or slight inconvenience to o perator or ao peration 2: a p ortion of the products h as to be rewo rked with minimal effo rt 3: a p ortion of the products h as to be rewo rked with moderate effort 4: all p rod ucts have to be scrapped or reworked with great effort 5: failure may end anger operator 4 Severity 1 2 Nr Risk 5 Consequence Counter Measure Back-up Scenario naald snel versleten bij grotere gewichten, meerdere doseurs nodig aanpassing doseur noodzakelijk betere positionering ZUP en naald snelle vervanging van naald mogelijk maken doseersnelheid opvoeren (bv door meerdere doseurs plaatsen gebruik van buffer) extra beweging van naald voorzien product beweegbaar opstellen Salt dosing slijtage van naald tegen ZUP-wand juiste zoutgewichten nog niet bekend positionering ZUP nog niet gedefinieerd werkt doseerprincipe voor alle zouttypes? (AlI3) Doseur haalt snelheid niet zout morsen Weight vervuiling van machine zout morsen 8 invloed van trillingen van machine vision onnauwkeurig op werking doseur (vision) LINAX heeft zich nog niet bewezen redesign nodig 9 hoekfout naald 7 trommeldoseur (enkel voor grotere gewichten) doseersnelheid opvoeren (bv door gebruik van buffer) meerdere doseurs plaatsen opvangbakjes op machine worden stofzuiger voorzien in de box voorzien result koppelingen juiste materiaalkeuze invreten op materiaal machine (vooral betere AlI3) LRL Gage R&r with limits +/-1µm: 5.59 Study Var %Study Var %Tolerance Source Gage R&R Total 5.57 Repeatability Reproducibility Operator Operator*Produktnumme r Mean: StDev: Cpk: aanpassing doseerprincipe of ander doseerprincipe nodig (is er niet!) meerdere doseurs nodig StdDev (SD) 0, , , , , flexibel zoekgebied uitwerken LCL voice coils ontwerpen voor grotere slag Target (6 * SD) 0, , , , , naald loopt tegen ZUP-wand en slijt snel (%SV) (SV/Toler) UCL 0,10 4,49% URL 0,08 3,47% 0,07 2,84% 0,00 0,00% 0,07 2,84% tolerantietrein in constructie optimaliseren? 10 vastlopen naald in ZUP door braam botsdetectie naald wordt geactiveerd controle bij eccentriciteitsmeting? of stof doseur werkt niet voice coil uitgewerkt 11 Piëzo units in Argon omgeving 29 statische ladingen zoutbollen plakkende bollen, moeilijk te doseren de-ionisatie apparatuur plaatsen 30 zoutvermenging slechte producten in de markt zoutpotjes specifiek maken per instructies aan operator zout zout verschillende diameter geven per type

15 Process flow Ultimo: maturity processes & equipment should be in phase with product life cycle Full automation (*) Step 3 Semi-automation Step 2 Process Step 1 Pilot Setup (*) Level of automation = f(tco)

16 Example Ramp up of the new platform

17 Hoe het begon 17

18 GEN4 Dosing & Sealing Glove Box

19

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