smt 2011
Post on 14-Jun-2015
407 Views
Preview:
TRANSCRIPT
Southern Manufacturing Technologies
2011
Business Segments• Aircraft• Aerospace• Defense• Commercial• Medical
Location• Tampa, FL• We have 90 employees
Capacity 67% as of 12/31/10
Customers• AeroControlex • Conax (Cobham)• Honeywell• Teledyne• Triumph• Woodward
Certifications• AS 9100• ISO 9001
Customers Certifications• Honeywell – MPC (Manufacturing Process
Control), Source Delegation• Triumph Actuation Systems – SIDA (Supplier
Inspection Delegation Authority)• AeroControlex – ACES (AeroControlex Excellent
Supplier)
Visit www.smt-tampa.com for a virtual tour.
Materials• Aluminum• Titanium• Stainless Steel• Inconel• Other metals
Stainless Steel Satellite Valve Assembly
Titanium Missile Defense Component
Anodized Aluminum Servo Valve Housing
Helicals Installed
Aluminum Servo Valve HousingsAnodized & Chem Filmed
Helicals Installed
Stainless Steel Parachute Release
Assembly
Titanium Atomizer Bells
Assembly Sectional View
Aluminum HousingMultiple Hard Coat Surfaces
Aluminum Deep Cover HogoutAnodized & Chem Filmed
Aluminum Cover HogoutAnodized & Chem Filmed
Aluminum Cover HogoutAnodized & Chem Filmed
Stainless Steel Rocket Valve Aluminum Housing HogoutAnodized & Chem Filmed
In-House Processing• CNC Lathes with Live Tooling• CNC Mills Vertical / Horizontal with full 4th axis and
5th axis positioning• CNC Waterjet Deburring• Ballizing• Grinding• Manual mills, lathes, Bridgeports, etc.
Subcontract Processing• Blast / Shot Peen• Broach• EDM• Grind / Hone / Lap• Heat Treat• Laser Part Mark• Waterjet cutting
Subcontract Testing• FPI• MPI• X-Ray• Ultrasound• Pressure Test
In-House Surface Treatments• Black Oxide• Chem Film
Subcontracted Surface Treatments• Anodize• Chem Film• Electropolish• Dry Lube / Dichronite• Paint• Passivate• Plating – Bronze, Chrome, Copper, Gold, Nickel,
Black Nickel, Tin• Sermetel
Collaborate with customers’ engineering department
• Machine-ability• Cost saving opportunities• Understand customers’ true needs• Inspection techniques• Value-added options (assembly)
Prototype• One-off capability• On premise engineering• Specialized Tool Room
Production Qualification• Small production run(s) to prove out process
Production• Ramp up into full production
New Part Team & Responsibilities:
Manufacturing Engineering• Collaborate with customers’ engineers• Specify Raw Material Size & Shape• Process Planning & Routing• Operation Drawings• Fixture Drawings• Special Tool Drawings• CNC Programs• Tool Data Sheets
New Part Team & Responsibilities:
Quality Engineering• In-Process Inspection Forms• AS9102 FAIR• Review & Approve Operation Drawings• Gage Request Forms• Production Count Sheets• Define Special Gaging
New Part Team & Responsibilities:
Purchasing• Order Material• Locate New Suppliers as needed
• Use NADCAP & customer approved suppliers as required
• Expedite Special Tooling & Gaging
New Part Team & Responsibilities:
CNC Supervisor• Collaborate with Manufacturing Engineers• Recommend Work Centers• Coordinate with other Key Personnel
New Part Team Summary:
New part team typically meets 2 – 5 times during the new part development process.
Team credentials:• Black Belt• Green Belts• NIMS Certified Senior Trainer• NIMS OJT Trainers• Certified Project Manager
Day (-32) RFQ ReceivedDay (-25) Completed Quote Sent to Customer
Day 1 PO ReceivedDay 3 Meeting 1 – New Part TeamDay 9 Raw Material OrderedDay 12 Meeting 2 – New Part TeamDay 15 Raw Material ReceivedDay 28 Meeting 3 – New Part Team – Process ReleasedDay 36 Production StartDay 36-65 Internal Processing Day 65-68 Outside ProcessingDay 69 Final Internal ProcessingDay 70 FAIRDay 73 Source Inspection & Ship
2 revision changes received before production start
New Part Summary
Part quoted with a 12 week lead time and delivered in less than 11 weeks.
“It has been a pleasure working with SMT throughout the entire procuring process. From the beginning you and your team were very responsive and very easy to work with. The parts you dropped off Monday look great, and our quality engineer who performed First Article Inspection commented on the quality of the part and your facility. It is not every day that a vendor provides a quality product and delivers a full week ahead of schedule. I am looking forward to working with SMT in the future and I just wanted to thank you for all your hard work.”
Many things, including, complexity, number and types of outside processes, and revision changes, influence the lead time and responsiveness.
“As I walked through the facility it was obvious there is a high level of value placed on the employees of SMT. The facility was very clean, organized, with machines strategically located, all good indicators of a committed and dedicated work team. There was also evidence of a strong emphasis on lean manufacturing practices which supports effective cost reduction opportunities.
Also obvious was the commitment to stay current with the latest machining capabilities. The machines are modern, appeared to be well maintained and strategically located to support the lean concept and most important, an AS9001 quality system. The installation of the water jet deburr machine is a significant addition to the overall operation.
In today’s supply chain environment where reduction and consolidation are the norm, first impressions are more important then ever and SMT shows well. As a participant of the Goodrich Corporation Interiors machining team I will include your company as a potential machining supplier to all Interiors sites of Goodrich, domestic and internationally.
My applause to SMT’s President, Roy Sweatman for successfully leading his company through these rough economic times and for preparing SMT for continued growth and success.”
Letter from 27 yr supply chain professional after tour of Southern Manufacturing Technologies, December 2010.
Letter from Goodrich buyer, 12/2010
• Lights out machining• 3 Horizontal Mills with twin pallets
• 2 machines with 300 tool magazine• 1 machine with 120 tool magazine
• 2 load stations• 23 pallets• Runs 24/7
• Unidirectional press• Carbide ball• Customized fixtures• Dimensional accuracy• 11 sigma process• Surface finish
Purpose• Quality• Consistency• Reliability• Efficiency• Cost Savings
KAN KH-6 Waterjet Deburring Center
New tooling added to Horizontal Mills
External burrs
www.harveytool.com
Internal burrs
www.jwdone.com
Kan KH-6 Waterjet Deburr Machine
Static Nozzle
Rotary Nozzle
Air Nozzle
x
y
z
b
0°-90°
v B Axis rotary table with 0°-90° tilt angle.
View from service door
v Arms and Tips with X Y Z movement.
View from service door
Fixtures & Work Holding
Part fixtures are designed in house for load and unload on the machine master pallets.
A magnetic sensor system recognizes the pin configuration, identifying the part being
processed, and loads the correct CNC program.Master
palletWork hold
fixture
Pin config
Master pallet Work hold
fixture
Pin config
B=0°B=90°
B=180°B=270°b
0°-90°
v Rotary nozzle • Used for internal deburring.• Comes with 7 Speed settings (200 to
900 rpm)
v Static nozzle• Used for washing cycles.
v Air nozzle• Used for blowing cycles.
Nozzles
Before & After
Tool Paths Used
A. Helical X Y Z movement• Using a custom macro
B. Z step movement• Using a custom macro
C. Contour X Y Z movement• Using Esprit CAD/CAM
Before implementation After implementation Final product
Machine Time Waterjet Manual Deburr
Before Implementation
1.24 Hr/pt 0 2.2 Hr/pt
After Implementation
1.34 Hr/pt 13 min/pt 54 min/pt
41% Total Improvement
-8% improvement 49 % improvement
Example: Complex Housing
Long-Term Agreements• Build to Forecasts• Build to SOI (Supplier Owned Inventory)• Build to VMI (Vendor Managed Inventory)• Build to Kanban• JIT (Just In Time) Delivery• NP Agreements
Awards won in 2010 by SMT
2010 NTMA Technology Award Winner
SHARP Award Winner, OSHA
Questions?
top related