Simultaneous product and production

development at Philips Turnhout

Hans Van Reusel - Philips Innovation ServicesGert Janssen - HID product development manager

Accelerate your innovationIntroducing Philips Innovation Services

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Accelerate your innovation

Philips InnovationServices

Concept Creation Support

A service provider

Industry Consulting

Sustainability, Safety & Health

Quality &Reliability

EquipmentDevelopment

Prototyping & Small Series

Product & ProcessDevelopment

Industrialization

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11/11/2013

PRODUCTIONPRODUCT DEVELOPMENT Philips Innovation Services GTDM

IndustrializationThe link between Product Development and Production

IndustrializationActivities and Competences

Concept

� Product co-

development

� Research

� Feasibility

studies

� Concept creation

� Consulting

� Lean solutions

Specification

� Industrial Setup

� Manufacturing

process

development

� Design for Six

Sigma

� Design for

manufacturing

� Prototyping

studies

� Concept freeze

Engineering

� Mechanical,

electrical and

software design

� FEM analysis

� System

integration

� Project

management

� CE - Safety

� Ergonomics

Realization

� Global sourcing

� Assembly

� Start & ramp up

� Training

� Repeats

Service

� Product range &

capacity

extension

� Productivity

improvement

� Spare parts

management

� Relocation

A track record of successful innovations …

Value Proposition Creation &Advanced Development

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

Product & Services Development &Market Introduction

Ideation & Innovation Planning

… aligning industrialization with the Philips Lighting Idea to Market process (I2M)

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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

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.

Define

Identify Design Optimize Verify

Monitor

Measure Explore Describe Improve Control

DfSS: a proactive method to design new products

MEDIC: a re-active method to improve existing products

8

9

The different stages of DFSS (DIDOV)

Mfg. Process CTQ Specs

Component CTQ Specs….

Subassembly CTQs..…

Subsystem Level CTQs…..

System Level CTQs…..

Design

Cp

Cp

Cp

Cp

Cp

Optimize & Verify

Voice of the Customer Needs

System Level Requirements

Subsystem Level Requirements

Subassembly Level Requirements

Component ‘Critical to Quality’ Requirements

Mfg. Process Requirements

Define & Identify

Example Salt dosing new gen CDM

11

GEN4 …. Complexity : Accent->Ultimo

1. Salt

2. Feedthrough

3. connection

4. Seal

5. ZUP

6. Antenna

Case salt doser (Bart L)

• Breakthroughs needed

• Size

• Accuracy

• ….

Projectname

MPCP Project Leader

Project Plan: ECP/MPCP PCP

MS-3 MS-2:

MS-2 mrt '09 MS-1:

MS-1 mrt '09 MS0:

MS0 okt '08 mrt '10 MS2:

MS1 jan '09 mrt '10 MS3:

MS2 jul '10

MS2+

MS3 jun'11

Processes Transl. customer

wishes to key end

product spec's

Colour process

steps: g(reen),

o(range), r(ed)

Alternative

processes

evaluated

Risk Maturity

Grid filled-in

Q-map Parameter

List

DoE's done Tolerance

analysis

done

Cmk at

required level

Parameters

future control

plan

identified

Required

%R&R

achieved

Risk

Maturity

Grid up-to-

date

SPD

report

ready

mercury dosing o ok ok ok ok ok ok for LTD ok ok ok 95%

salt dosing o ok ok ok ok ok ok ok ok ok 90%

plug dosing r ongoing ok ok 80% 75% ok ongoing

SPD step finished? (yes = "ok")

Processes Verify parameter

settings

Process

FMEA

Control

plan finished

Verify %R&R Short term

Cpk

Control charts

available

Long-term

Cpk

OCAP's

available

mercury dosing ok ready ready 12% 1.45 ok 1.32 80%

salt dosing ok ready ready 8% 2.13 ok 1.86 75%

plug dosing ok ready ready 5.60% 1.89 ok 1.64 60%

SPD step finished? (yes = "ok")

SPD Step 7 - 8

Perform verification on mechanised equipment

from MS1 to 2

SPD Preparation Phase SPD Step 1-3

Describe and identify

from MS2 to 3

ok

SPD Step 9 - 10

Assess control

SPD Step 4 - 6

Analyse and

Optimise

ok

SPD Step 7 - 8

Perform verification on test equipment (PMO)

SPD completion score

Ulimo Enter data in yellow fields only!

Ward Cottaar

from MS -1 to 0

IndustrializationMPCP: how?

•Define assignment

•Identify critical processes

•Evaluate multiple alternatives

•Create risk overview

•Make proces descriptions

•Set-up proces flow

•Set-up Qmap / critical parameter

overview

•Extensive testing (DoE) of identified

critical parameters

•Define proces windows

•Build tolerance analysis

•Validate chosen solution

•Define production- & test- equipment

•Update risk overview

•Verify on final production set-up

•Define final settings

•Measure performance

•Monitor long term performance

• MPCP philosophy ingrained in our organization for over 10yrs

• Green and Black belt training programs support this way of working

• MPCP philosophy crosses boundaries product development –machine creation

Processes Transl. customer

wishes to key end

product spec's

Colour process

steps: g(reen),

o(range), r(ed)

Alternative

processes

evaluated

Risk Maturity

Grid filled-in

Q-map Parameter

List

DoE's done Tolerance

analysis

done

Cmk at

required level

Parameters

future control

plan

identified

Required

%R&R

achieved

Risk

Maturity

Grid up-to-

date

SPD

report

ready

mercury dosing o ok ok ok ok ok ok for LTD ok ok ok 95%

salt dosing o ok ok ok ok ok ok ok ok ok 90%

plug dosing r ongoing ok ok 80% 75% ok ongoing

SPD step finished? (yes = "ok")

Processes Verify parameter

settings

Process

FMEA

Control

plan finished

Verify %R&R Short term

Cpk

Control charts

available

Long-term

Cpk

OCAP's

available

mercury dosing ok ready ready 12% 1.45 ok 1.32 80%

salt dosing ok ready ready 8% 2.13 ok 1.86 75%

plug dosing ok ready ready 5.60% 1.89 ok 1.64 60%

SPD step finished? (yes = "ok")

SPD Step 7 - 8

Perform verification on test equipment (PMO)

from MS -1 to 0

SPD Step 7 - 8

Perform verification on mechanised equipment

from MS1 to 2

SPD Preparation Phase SPD Step 1-3

Describe and identify

from MS2 to 3

ok

SPD Step 9 - 10

Assess control

SPD Step 4 - 6

Analyse and

Optimise

ok

IndustrializationMPCP: example

Processes Transl. customer

wishes to key end

product spec's

Colour process

steps: g(reen),

o(range), r(ed)

Alternative

processes

evaluated

Risk Maturity

Grid filled-in

mercury dosing o ok ok

salt dosing o ok ok

plug dosing r ongoing ok

SPD Preparation Phase

ok

Bulk

200µm 800µm

One by one

Probability

5 OK

4 24, 25NOK but

will be

fixed

33, 6, 10,

31

2, 5, 13,

29

9, 12, 23,

26, 27, 30

Show-

stopper

2 21 14 8, 22, 28 4

1 15, 32 1, 18 Severity

1 2 3 4 5

Nr Back-up Scenario

1 snelle vervanging van naald mogelijk maken

2 meerdere doseurs plaatsen

3 product beweegbaar opstellen

4 trommeldoseur (enkel voor grotere gewichten)

5 meerdere doseurs plaatsen

6 stofzuiger voorzien in de box

7

8 voice coils ontwerpen voor grotere slag

9

10

11

29

30 instructies aan operator

Salt dosing

tolerantietrein in constructie

optimaliseren?

doseersnelheid opvoeren (bv door

gebruik van buffer)

naald snel versleten

bij grotere gewichten, meerdere

doseurs nodig

vervuiling van machine

vision onnauwkeurig

redesign nodig

doseur werkt niet

plakkende bollen, moeilijk te doseren

slechte producten in de markt

de-ionisatie apparatuur plaatsen

Doseur haalt snelheid niet

zout morsen

invloed van trillingen van machine

op werking doseur (vision)

LINAX heeft zich nog niet bewezen

hoekfout naald

aanpassing doseur noodzakelijk

doseersnelheid opvoeren (bv door

gebruik van buffer)

extra beweging van naald voorzien

controle bij eccentriciteitsmeting?

flexibel zoekgebied uitwerken

juiste materiaalkeuze

opvangbakjes op machine worden

voorzien

betere koppelingen

meerdere doseurs nodig

positionering ZUP nog niet

gedefinieerd

zout morsen

voice coil uitgewerkt

naald loopt tegen ZUP-wand en slijt

snel

zoutpotjes specifiek maken per

zout

zout verschillende diameter geven

per type

statische ladingen zoutbollen

zoutvermenging

werkt doseerprincipe voor alle

zouttypes? (AlI3)

botsdetectie naald wordt geactiveerdvastlopen naald in ZUP door braam

of stof

invreten op materiaal machine (vooral

AlI3)

Piëzo units in Argon omgeving

aanpassing doseerprincipe of ander

doseerprincipe nodig (is er niet!)

Counter Measure

betere positionering ZUP en naald

juiste zoutgewichten nog niet

bekend

slijtage van naald tegen ZUP-wand

Risk Consequence

Probability:1: failure unlikely, <1 ppm2: relatively few failures, 10 ppm3: occasional faiures, 1 in 10004: frequent failures, > 1 in 205: failure inevitable, > 1 in 3

Severity (customer effect):1: no noticable effect2: aesthetic failure, defect noticed by discriminating customers3: item operable but comfort/convenience is compromised. Most customers dissatisfied.4: item inoperable. Customer dissatisfied.5: unsafe operation/ non-compliance with regulation

Severity (manufacturing/ assembly effect):1: no or slight inconvenience to operator or aoperation2: a portion of the products has to be reworked with minimal effort3: a portion of the products has to be reworked with moderate effort4: all products have to be scrapped or reworked with great effort5: failure may endanger operator

Gage R&r with limits +/-1µm:

Study Var %Study Var %Tolerance

Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)

Total Gage R&R 0,0000224 0,000135 0,10 4,49%

Repeatability 0,0000174 0,000104 0,08 3,47%

Reproducibility 0,0000142 0,000085 0,07 2,84%

Operator 0,0000000 0,000000 0,00 0,00%

Operator*Produktnumme r 0,0000142 0,000085 0,07 2,84%

Q-map Parameter

List

DoE's done Tolerance

analysis

done

Cmk at

required level

Parameters

future control

plan

identified

Required

%R&R

achieved

Risk

Maturity

Grid up-to-

date

SPD

report

ready

ok ok ok ok for LTD ok ok ok 95%

ok ok ok ok ok ok ok 90%

ok 80% 75% ok ongoing

SPD Step 7 - 8

Perform verification on test equipment (PMO)

SPD Step 1-3

Describe and identify

SPD Step 4 - 6

Analyse and

Optimise

ok

Verify parameter

settings

Process

FMEA

Control

plan finished

Verify %R&R Short term

Cpk

Control charts

available

Long-term

Cpk

OCAP's

available

ok ready ready 12% 1.45 ok 1.32 80%

ok ready ready 8% 2.13 ok 1.86 75%

ok ready ready 5.60% 1.89 ok 1.64 60%

SPD Step 7 - 8

Perform verification on mechanised equipment

SPD Step 9 - 10

Assess control

5.57

5.575

5.58

5.585

5.59

5.595

5.6

5.605

5.61

5.615

Weight

result

LRL

LCL

Target

UCL

URL

Mean: 5.5995 StDev: 0.0018 Cpk: 1.9406

Pilot Setup

Process

Semi-automation

Full automation (*)

Step 1

Step 2

Step 3

Process flow Ultimo: maturity processes & equipment should be in phase with product life cycle

(*) Level of automation = f(TCO)

Example Ramp up of the new platform

17

Hoe het begon…

GEN4 Dosing & Sealing Glove Box

www.openmanufacturingcampus.com

info@openmanufacturingcampus.com