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Commonality Tool Overview PL5M, PLC2, & PL83 part commonality recommendation process and tools.

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Presentation on theme: "Commonality Tool Overview PL5M, PLC2, & PL83 part commonality recommendation process and tools."— Presentation transcript:

1 Commonality Tool Overview PL5M, PLC2, & PL83 part commonality recommendation process and tools

2 Katy Whitcher T: Commonality Tool Overview Agenda Commonality Tool Development Process Commonality Recommendation Process Common PL83 & PLC2 PCA Analysis Example Questions?

3 Katy Whitcher T: Commonality Tool Development Process Identify Functional Design “Chunks”* *Chunks describe the set of components that perform a specific function Identify “Chunks” with Common Function Across Designs Identify all Costs Drivers Associated With Unique Designs of Chunks Determine Which Chunks can Feasibly be Made Common (Constraints such as ID). We broke the chunks into two groups EE and ME. Estimate Cost Driver Magnitudes and Prioritize Based on Agreed to Cut-off Develop Tool to Compare Cost of Unique “Chunks” to Cost of Common “Chunks” Validate Algorithms in Tool with Key Stakeholders Agree on Process for Applying Tool and Map to PLC

4 Katy Whitcher T: Chunk List for PL83, PLC2, & PL5M Carriage board Main Logic Board Digital ASIC Analogue ASIC Power Supply Sensors Scan Module Fax Module Control Panel Servo/Motors Chassis’ Case Parts Service Station Paper Path Carriage IDS Trays Carriage Flex Main Wiring Harness Cables (other) Electrical Components Firmware Writing Systems

5 Katy Whitcher T: Chunk List with Commonality Opportunities EE Engineering* Main Logic Board Digital ASIC Power Supply Sensors Control Panel - LCD Electrical Components ME Engineering* Trays Main Wiring Harness Cables (other) Firmware Writing Systems I-Mix Opportunity Product schedule Platform schedule Product schedule Product & Platform schedules Platform schedule *We simplified the tool development by combining “chunks” into similar design categories, EE & ME

6 Katy Whitcher T: Cost/Benefit Framework for EE Common PCA Example Better negotiation of DM$ Logic PCA - $30 Newport Plus Logic PCA - $40 CaBo + Video Board - $10 Logic PCA - $30 CaBo&Newport Video Board $20 CM MOH savings Common fixtures CM head count HP head count Inventory mgmt. Service & support MOH RMA PCA return EOL exposure CM labor CM space Inventory stocking Increase in DM Ease of mgmt NRE changes PCA process development Qualification Design quality AOS management Doesn’t change with current policies Improves – 1 P/N v.s 3 P/N Qualification needs to be done only once QD test savings, PCA qual FW roll happens on common board Solving qty issues simplify +$ -$ +$ Legend Included in commonality analysis tool Assembly Time

7 Katy Whitcher T: VPP Tray HPP Tray AiO Tray Common Tray Tooling $ Raw material Molding Inventory stocking Development/qualification time AOS/Inventory Mgmt. Quality Packaging Ease of mgmt. Change in DM$ Service&support Potential to reduce # of tools Effect tool design cost Economies of scale (I.e. id same resins are used Economies of scale Set-up, downtime Assembly cost Does not change with current policies Leverage, shorter LT to qualify Subsequent tools Learning can be quickly transferred to subsequent PLs (reuse procedure & training simplify Supplier MOH Ability to cater to mix shift changes If DM issue will impact all PLs Standardized package may save $ Reduce part numbers from re-use partners Need to add effect of manufacturing in multiple regions Legend Included in commonality analysis tool Cost/Benefit Framework for ME Common Input Tray Example

8 Katy Whitcher T: Cost Driver Prioritization Prioritization Steps Agree to significant ranges for cost drivers. How many Step size Assign range to each cost driver. Agree on the cut off range for including a cost driver in the model. Discuss each cost driver above the cut-off for inclusion in the model. Is the cost driver quantifiable? Is it something we can predict? Decide if the items should be included in the model. Eliminate insignificant or uncontrolled cost drivers

9 Katy Whitcher T: Commonality Tool Overview The Commonality Tool is a set of Excel spreadsheets that convert user entered part DM, resource usage, supply chain management, and NPI data for a variety of part selection scenarios into a total cost comparison of the scenarios. DM cost, engineering resource investment, out sourcing costs, supply chain information, and life plans for the different scenarios are entered into the “Inputs” spreadsheet. Sensitivity of the cost comparison can be performed on product volumes, DM cost, inventory management plans (WOS & scrap) and impact of expediting components via air shipments using the “Sensitivity” spreadsheet.. The “Intermediate Calcs” spreadsheet allows the user to identify which unique parts can be combined into common parts. Default values for WOS, scrap, salvage value, and IDC rate are also set on this spreadsheet.

10 Katy Whitcher T: Platform PLC Various Program PLC’s Cross Platform I-Mix Schedule & Deliverables D/O I/LL/PMR D/O I/LL/PMR At Platform D/O: Present commonality recommendations to Platform Team By 1 st Program D/O: Recommendations to Program Teams (HPP or AIO Program) By 1 st Program I/L: Validate data in commonality tool & ensure PL and Program Teams aligned By Program MR: Finalize I-Mix cost benefits for IPMO/PL M/R Checkpoint Presentations Commonality Tool Recommendation Process

11 Katy Whitcher T: Detailed Recommendation Process Flow

12 Common PLC2 & PL83 PCA Example PIP Common Electronics Investigation

13 Katy Whitcher T: Feasible Options Input data for each unique and common design Choose unique designs to combine into a common design. Perform sensitivity analysis. Commonality Investigation Process Overview Unique Design Common design candidate

14 Katy Whitcher T: PIP ’05 Common Electronics Investigation Current POR. On-board DPS for PIP-N and on-board card slots for PIP-S. PIP-N PCA DPS PIP-S PCA DPS Card Slots $2.00 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $2.40 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $3.00 for card slots

15 Katy Whitcher T: Option 1 – Common design with PIP-N implementing subset of PIP-S schematic or PCA PIP-N PCA DPS No Load or remove PIP-S PCA DPS Card Slots $2.90 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $3.00 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $3.00 for card slots Assume no added R&D to design and maintain common schematic. This is current default and savings over previous years, (enabled by common ASIC and collaboration). PIP ’05 Common Electronics Investigation

16 Katy Whitcher T: Option 2 – Common design with modular card slots PIP-N PCA DPS PIP-S PCA DPS Card Slots connector $2.90 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $0.40 for connector $3.00 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $3.00 for card slots $0.80 for connectors Same as option #1 with connectors for card slots. PIP ’05 Common Electronics Investigation

17 Katy Whitcher T: Option 3 – Common design and PCA with USB card slots PIP-N PCA DPS PIP-S PCA Card Slots connector $2.90 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $0.02 for connector $3.00 for PCB $16.00 for components – Z-lite & Del Sol $0.25 for Pict Bridge $3.00 for card slots $1.50 for USB interface and connectors DPS PIP ’05 Common Electronics Investigation


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