1. Design for Manufacturability

2.  Raise engineer’s design skill level  Improve quality of design  Improve quality of documentation  Enable higher quality, more cost effective manufacturing  Produce products more easily PRG/TBC2

3.  Simultaneous, Early Consideration Of All Design Goals & Constraints  Optimizes Efficiencies From Initial Concept Through Product Life.  Results In Lowest Total Cost & Shortest Time To Market. PRG/TBC3

4. Business Challenge

5. Elect. Design Ind./Mech. Design Software Dev. Proj. Mgmt. Bus. Process Test Dev.Proto Mfg. Packaging/ Logistics Vol. Mfg. Quality/ Reliability Fulfillment/Rep air FinanceMktg/Sales HR Cust. Reqn’tsProd. Def. Business Challenge

6. Lack of Technical Expertise: Internal resources often lack sufficient or appropriate technical expertise to support projects. Project Management and Integration: Internal resources have limited bandwidth to manage multiple outside partners effectively. Resource Availability: Internal resources are not always available in the timeframe required to meet project needs.

7. Spreadsheets Emails Faxes Changes BOMs New Part Requests Engineering ? Manufacturing Product Revisions? Current BOM? New Part Signoffs? Contract Manufacturers tied into change control?  Product is not what customer wants  Costs are too high  Product is not manufacturable or supportable  Unable to achieve compliance (ISO, FDA, RoHS, etc.)  Missed business plan targets

8.  Product Design Costs 5% Of Total Product.  Product Design Determines 70% Of Total.  To Reduce Costs - Focus On Design.  Allocate/Move Resources “Upstream”. PRG/TBC8

10.  Product Design ◦ Inventory cost impact ◦ Engineering documentation ◦ Customer service costs ◦ Quality risks ◦ Material & direct labor ◦ Administrative costs ◦ Customer response time ◦ Capital equipment costs PRG/TBC10

11. PRG/TBC11 Design Prototype First production Launch DEVELOPMENT STAGES COSTCOST Cost of changes multiplies By 10 with each step 10100100010,000

12.  Process Challenges  Guidelines for Assembly  Fundamental Considerations PRG/TBC12

13.  American Airlines ◦ Fleet of 12 different aircraft = 11 x cost  Southwest ◦ Fleet of 737 aircraft = streamlined cost

14. PRG/TBC14

15. PRG/TBC15

16. PRG/TBC16

17.  Product Lifecycle Management (PLM) ◦ Supports the extended enterprise  Customers, design, and supply partners ◦ Integrates  People  Processes  Business systems and information 17

18. A set of capabilities that enables an enterprise to: – Manage its products and related services throughout the entire business lifecycle Total Business Consulting Group18

19. Manufacturing Planning Full Production Service and Support Concept and Planning Design and Engineering PLM provides a data platform for managing forward processing of data, AND recycling it back for subsequent products. CAD/CAE Web, Excel, Visio, etc. PDM cPD Visualization SCM/SRM CRM ERP/MRP What is Product Lifecycle Management (PLM)?

22.  Traditional serialized product development process ◦ When does the Mfg./Production Engineer see the final design? ◦ What happens next?  Changes begin  How many changes do you initiate? ◦ How do we classify the changes?  Mandatory vs. phase-in PRG/TBC Group 22

23. Resistance – Lack of familiarity and FEAR Global Issues – Distance/language Lack of Champion – Driving force Lack of Measurement – Where are we? – What is the ROI? 23

24. PRG/TBC24 Q and A