Reducing Scrap and Rework John Buchowski Director, MCAD Product Management PTC

Forward Looking Information Subject to Change without Notice © 2006 PTC2 Scrap and Rework…. Can the application of PLM technologies lead to reductions in scrap and rework in product development? Agenda of presentation Causes of scrap/rework –Which of these causes can be addressed with PLM technologies Customer challenges/problems Technology Solutions

Forward Looking Information Subject to Change without Notice © 2006 PTC3 Scrap and Rework…. What are some of the core causes of scrap and rework? Wrong designs manufactured –Duplicate parts –Incorrect versions Parts/components as manufactured do not meet quality standards –Injection Molded components with sink marks? Short shots? –Poor tolerances, components cannot be assembled…. Designs that fail to satisfy requirements –Aesthetic –Functional –Ergonomic All of these can be significantly impacted by implementing PLM technologies and processes

Forward Looking Information Subject to Change without Notice © 2006 PTC4 Typical “As-Is” Design Communication and Data Sharing The Big Culprits: Network Folders, FTP, Ad Hoc / Paper Processes

Forward Looking Information Subject to Change without Notice © 2006 PTC5 Are There Opportunities For Improvement? RoHS APQP 21 CFR Part 11 How do you insure remote sites, suppliers and customers are working from the correct versions of information? What is the significance of achieving and maintaining regulatory compliance? How quickly can you respond when sales changes customer requirements (ECNs, ECOs)? How much time do your teams spend searching for information? How do you ensure it’s the right version? How do you promote reuse? How is Bill of Material (BOM) information exchanged between Design and Production?

Forward Looking Information Subject to Change without Notice © 2006 PTC6 PLM As The Backbone For Improvement 1.Centralized Data Vault  Revision / Lifecycle Control  xCAD (parts, assys, etc)  Document Management  Visualization  Access with Web browser 2.Change Management  Change Visibility / Notification  Documents, Drawings, BOM  Problem Reports, ECRs, ECNs  Metrics and Audit Trail 3.Collaboration / Sharing  Virtual Design Teams  External Partners (Design & Mfg)  New Product Introduction  Quality & Compliance 4.Integration with MRP / ERP  Change Activity  Approved Vendors / Manufacturers  Common BOM Driving Operations Company-wide

Forward Looking Information Subject to Change without Notice © 2006 PTC7 Design Control/Design Communication No company is too small, or product too simple to leverage for effective product data management Problem…  What version of a design has been delivered to manufacturing?  Are there pre-existing components we can choose from?  Are these parts from an approved supplier?  Have these parts been released to manufacturing?  How can we effectively share this design data with our supplier? Solution…  Implement PDM solutions to manage and communicate design data Best Practice

Forward Looking Information Subject to Change without Notice © 2006 PTC8 Manufacturing Standards and Quality Do your designs satisfy manufacturing requirements? Ways to validate manufacturing requirements –Tolerance analysis We designed it, made it, will it fit together? –Mold flow/filling –Model checking/standards checking Bend lines too close to edge of parts, etc… –Toolpath validation As with design communication challenges, many of these can be addressed without much difficulty….

Forward Looking Information Subject to Change without Notice © 2006 PTC9 Product Fit/Tolerances Don’t wait until an early production run to uncover tolerance stack up issues…. Problem…  Is this design toleranced appropriately?  Will the product fit together when manufactured?  How many of the units assembled will end up as scrap? Solution…  Perform quick, up-front tolerance stack checking for critical dimensions Best Practice

Forward Looking Information Subject to Change without Notice © 2006 PTC10 Product Manufacturability Many manufacturability issues can be addressed long before soft tooling…. Problem…  Is this design suitable to be molded?  Will there be sink marks or knit lines on visible surfaces?  Can I provide insight as to where the part should be gated? Solution…  Use manufacturability design checking solutions  Design with manufacturability in mind as though for any other constraint Best Practice

Forward Looking Information Subject to Change without Notice © 2006 PTC11 Design Rules for Manufacturability Apply rules checking tools to ensure basic design/manufacturing standards are adhered to Problem…  Are standard sheetmetal thicknesses used?  Are allowable materials called out?  Are company naming conventions and standards adhered to?  Does the model contain small edges, inaccuracies, or other difficult to manufacture geometry? Solution…  Use design rules and model checking solutions as gatekeepers in the design to manufacture handoff Best Practice

Forward Looking Information Subject to Change without Notice © 2006 PTC12 Designs satisfying design requirements As a product is developed, a failure to address design requirements can lead to costly rework….  Aesthetic  Functional  Ergonomic Leveraging traditional and non-traditional simulation technologies can significantly reduce rework

Forward Looking Information Subject to Change without Notice © 2006 PTC13 Aesthetic Requirements Problem…  What will the product look like?  Will consumers like the color choices?  Are we satisfied with materials and texture choices? Solution…  Photorealistic renderings of models can be used to validate design and stylistic decisions early in the development process Pay attention to visual quality – details captured in design models will be leveraged in the aesthetic mockup Best Practice

Forward Looking Information Subject to Change without Notice © 2006 PTC14 Dynamic/Kinematic Requirements Leverage Motion Skeletons to support top-down design techniques incorporating the correct rotational and translational degrees of freedom of your system Best Practice Problem…  Will the design move as intended?  Is this actuator sized properly?  Will these bearings support the loads in the assembly? Solution…  Investigate kinematics before moving to physical prototyping

Forward Looking Information Subject to Change without Notice © 2006 PTC15 Structural Requirements Developing “mentoring” programs is the most effective means of proliferating use – broad based adoption in the design ranks pays the greatest dividends Best Practice “Best in class manufacturers are 63% more likely to provide CAD-embedded simulation to their engineers.” Problem…  Is this design strong enough?  Will we have fatigue/durability issues?  Will the product bend/deflect too far? Solution…  Apply functional simulation early and often in the design process to minimize surprises and late phase rework…

Forward Looking Information Subject to Change without Notice © 2006 PTC16 Human Factors/Ergonomics Don’t push ergonomics/human factors validation until the end of the design process. Uncover issues early that would in the past be identified during first build Best Practice Problem…  How will a user interact with the product? Will they be able to…  Lift a load?  See a control panel?  Reach a switch?  Operate a machine comfortably? Solution…  Add a “Digital Human” to your environment  Include ergonomics validation from the very beginning of the design

Forward Looking Information Subject to Change without Notice © 2006 PTC17 Real World Success Story RollEase: Integrated Product Development for Global Design and Manufacturing

Forward Looking Information Subject to Change without Notice © 2006 PTC18 Conclusion Application of PLM technologies can effectively reduce scrap and rework Many root causes of scrap and rework can be effectively addressed –Failure to satisfy design requirements –Manufacturability issues –Design Communication/Control The right data At the right time To the right people As with many problems, addressing earlier is more cost effective than waiting….

Forward Looking Information Subject to Change without Notice © 2006 PTC19 Thank You!