Who are we ????

1
Who are we ????

• Sean Davies
• VP president of operation, Federal Division
• EMBA Professor of Operations and Project
  Management at Loyola
• 15 years experience in manufacturing operations

2
Who We Are ????

• Process and Capacity Improvements
• Capability Studies
• Partnered with Society of Manufacturing Engineers
• Authorized Representative of Tooling U

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Encoeur, SME, Tooling U???????????????????????
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?????????SME??70??,??????????????????SME??????????
??????????????????????????????????SME???50????????
????????,??70????????? ??????????????
??(Boeing),??????(Pratt Whitney), ????
(Raytheon), ???(GKN), Whitcraft LLC, Heroux
Devtek?? ???????(DaimlerChrysler), ABB??(ABB),
????????(American Axle Manufacturing),????(Arvin
Meritor),??(Federal-Mogul),??(Honda),??(Toyota),??
??(International Truck Engine
Corp),???(Volvo)?? ?????(JDS Uniphase), Rittal
Corporation, ????(Tyco Electronics),???(Leviton
Manufacturing Co Inc)?? ????(Baker Hughes),
??????(GE Energy), ?????(Siemens
Power),????(General Electric Company),
??(Flowserve), ????(National Oilwell
Varco)?? ????(Eaton Hydraulics), ?????(Kennedy
Valve), ?????(Parker Hannifin), Graco
Inc?? ????(Caterpillar), Excel Foundry Machine,
???(Rosenboom Machine Tool Inc),???(Sauer
Danfoss), ???(Cummins Inc)?? ????(Kennametal
Inc),???(Mazak Corporation), Seco?? (Seco Tools,
Inc), SGS??(SGS Tool Company)??
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My Team ??????

• Grant Johnson- Processes
• Mike Agronin- Engineering
• Michael DiPietro- Materials
• Brian Smith- Process, Training
• John Hartley- Process, Business Develpment

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Capacity ??

• What is capacity? ?????
• Macro Capacity- economic potential of a facility
• ????
• Effective combination of the Micro Capacity
  Macro Capacity
• ??????????????
• Micro Capacity is the processes
• ????????????

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Factors for Micro Capacity Issues???????????

• Capacity gapinefficiency ???? ???
• Bottle neck ??
• Facility Layout ????
• Resource Management ????
• Materials Management ????
• Process Planning ????
• Quality Issues ????

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Capability study????????

• Labor cost ????
• More equipment purchase ????
• Machine capability ??????

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Examples to be share????

• Federal Government ??????
• NASA ???????
• General Motors ????
• Harley Davidson ?????
• General Electric ????
• Siemens Medical Systems ???????
• Hewlett Packard ??
• Others ???

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Case Story- Digna Machine Shop??Digna??

• Backlog Issues ??
• More Shifts ??
• Implemented Material Control Systems ??????
• Process Development ??????
• Plant Layout ????
• Tool consolidation ??????
• Project management plans ??????
• Result- Increased from 10,000 Pieces to 20,000
  Pieces- Capacity 100 for 3 months
• ??3???????

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Case Story- GE ??? ????

• Laser Cloth Slitting for MRI systems
• ??????????(??????)
• Capacity Study (????)
• Capability study (????????)
• Process Changes (??????)
• Result- increase in production from 72,000 sq in
  to 216,000 sq in- capacity by 300
• ??3?????

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Case Story- Harley Davidson????????

• 5 Axis Oil Pan Cutting (???????)
• Created Continuous process (?????????)
• Increased Capacity from 350 pieces a day to 1400
  300 (6?????)

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Case Story- US Army ???????

• War time ramp up for artillery shells
• (???????????)
• New Process of Horizontal Machining with Pallet
  change(HAAS EC500)
• ??????(?????)?? ???
• Created tooling, training inspection process
• (??????????????)
• Result-Increased Capacity by 200
• ??????2?

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Case Story- NASA??????????

• Satellite Propulsion Arms
• ???????
• Trepan Drilling to Percussion Drilling
• ???????
• Result- Increased Quality from 70 to 100
• ?????70???100
• Result- Increased Capacity from 4 parts a day to
  8 a day- 100
• ??????1?

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Capacity study????

• Keys ????
• What is the current capacity ????
• What is capability study (technology) ???????
• What is process improvement (flow) ??????
• Capability work with process (ideal vs practical)
  ???????????(???????)
• Maintain quality ????

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US manufacturing problems 2008-present2008???????
????

• More manufacturing outsourced ??????
• Less machine investment ????????
• Market recession ????
• Gas price ????

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Manufacturing Trends in US???????

• Financial and Economic Problems ???????
• Unemployment 12 going to 6 ?????
• Election Year ???
• Manufacturing education ????
• Online education

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Manufacturing Trends in US???????
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Manufacturing Trends in US???????
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Manufacturing Trends in US???????

• Closed Capacity Gap ??????
• Increased Capacity ????
• Improved Processes ??????
• New Technologies ???
• Result- Lower cost ????
• Quality product ?????
• On Time Delivery

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?????????

• Robot ???
• AI ????
• 3D printing 3D??

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Accomplishments-Grant Johnson ????

• Agilent Technologies
• Led a team manufacturing medical devices to an
  increase in revenue of 10 times, meeting shipment
  goals for 4 consecutive quarters
• During the ramp-up findings from internal quality
  audits were reduced by 78, and an ISO 9001 audit
  was passed successfully with zero (0)
  nonconformances
• ELDEC Corporation ??ELDEC??????
• reduce proximity sensor laser welding failures
  (program savings of 756K)
• reduce soldering defects by 96
• reduce design cycle time for an instrumentation
  amplifier(????? )by 50 and improve sensitivity
  of amplifier(??????) by 100

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Accomplishments-Brian Smith

• Opto Mechanical Inc
• Changed set up practices and facility training
  and layout to increase productivity by 30
• Wegmann USA
• Implemented ISO 9001 Quality standards
• Ensured Military specifications met
• Trained all floor personnel on machines including
  program editing, set up and operation
• Implemented process optimization to increase
  production by 25 and reduce scrap by 50

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Accomplishments-Brian Smith

• Sonnys Automotive Racing
• 5 axis CNC programing, fixtures and tooling for
  engines
• Cylinder head porting projects contributed to
  world championship in pro stock drag racing
• Advanced Manufacturing Technical education center
• Trained over 1,000 students in the latest CNC
  techniques including advanced manufacturing
• Trained US military on CNC equipment

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Advanced Technology Experiences??????

• 5 axis machining 5???
• 5 axis waterjets 5???
• 5 axis Laser- CO2 and NdYag 5???
• Laser Heat Treating ?????
• Laser Welding ????
• Image Scanning- Cloud Point Imaging ????????
• 3D Rapid Prototyping- SLS, SLA, plastics
  3D??(??????)

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• Questions?

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• Thank You

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Approach- Process Improvements

• Review your process flow and look for ways to
  optimize layout of equipment and process flow
• Review work orders and information within packets
• Recommend software improvement to create better
  tracking tools to monitor production
• Tool review to make sure you have the right tools
  to produce the outcomes you want

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Approach- Cost Reductions

• Review of systems for cost improvements
• Look at material flow and usage to maximize
  efficiencies
• Review Personnel- do we have the right people
  doing the right jobs?
• Material negotiations

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Approach- Quality Management

• Apply our experience in
• ISO
• Automotive
• Department of Defense
• Aerospace
• To work with your Quality team to enhance what
  you have to meet international standards

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Approach- Supply Chain Management

• Review of Material needs
• Look for economies of scale in ordering
• Define process flow needs to maximize production-
  no machines waiting on material
• Negotiate better pricing
• Look for international suppliers

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Approach- Financial Management

• Review profitability of organization, teams and
  jobs
• Look for financial performance improvements to
  meet the needs of the shareholders
• Financial advice on leveraging monies and assets
  for long term financial goals

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Approach- Preventative Maintenance Programs

• Review of your Maintenance Plans
• Build Equipment Plans to increase longevity of
  equipment and up time
• Create tracking system to ensure plan is
  implemented
• Annual review of plan

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Approach- Technical Training

• On line SME training tools
• In house technician training
• Custom developed training programs for your teams