1. DESIGN OF A RATING SYSTEM FOR SUPPLIERS OF PRINTED WIRING BOARDS AT HAMILTON SUNDSTRAND By: Travis Bossidy, IE And Patrick Dabrowski, IE Industrial Advisor: Steve Webster Faculty Advisor: Dr. Abdul Kamal

2. Introduction Needs to improve the way they rate supplier quality for printed wiring boards (PWB). Current system uses PPM Problem: system only takes into account number of defective parts Other aspects of quality have to be considered

3. Problem Statement A supplier quality rating system that rates all aspects of supplier quality in order to monitor and compare suppliers of PWB

4. Components of Supplier Quality PPM Complexity Criticality PAIN

5. PPM Number of Parts Per Million defective (Quantity Defective/Throughput)*10 6 = PPM Only takes into account quantity of defective parts

6. Complexity All PWB differ Simpler parts are easier to make according to specs Suppliers need to be rewarded for making complex parts

7. Criticality Defects differ in how they affect the part Some defects are not as serious as others

8. PAIN Where in the process the defect is located Further along in the process, the more value added Hamilton Sundstrand's “Rule of Ten”

9. Rating System All four components will be placed into an equation The value will be in adjusted PPM (PPM NEW ) The PPM NEW can be higher or lower than the original PPM

10. The Equation The original PPM equation will be used Each additional component will be represented by a factor The output of the equation will be PPM NEW Median values for each component will be needed

11. Component Factors Complexity – Scale of 1-4 – 4 being the most complex – Factor determined from sum of 11 different complexity characteristics – Median value is 2.5, linear relationship – Limits for this scale created by histogram method using Tyco's complexity data

12. Component Factors (continued) Complexity histogram – TYCO had their PWB summed and rated – Hamilton Sundstrand only wanted 11 of the 21 characteristics included. – Sum was recalculated, were redistributed in the scale attempting to mirror the same percentages

13. Component Factors (continued)

14. Criticality – Scale 1-10 – 10 being the most critical defect – If there is more than 1 defect, then the highest value is used – All possible defects were recorded and factor were given – Median value is 5.5, linear relationship

15. Component Factors (continued) PAIN – Each step in the process was assigned a value from 10-1000 – 10 being receiving inspection, 1000 being field failure – Steps had to be assigned numeric values

16. Component Factors (continued) PAIN (continued) – Graph was created with numeric steps and Pain – Then an equation was determined using a trend line w = 1.155e 2.1692 X Where: w = PAIN associated with step x = Numeric value of step in the process

17. Component Factors (continued) w = 1.155e 2.1692 X Where: w = PAIN associated with step x = Numeric value of step in the process

18. Component Factors (continued) PAIN (continued) – Equation had to be normalized – Divided by a factor of 10 – This put it on a 1-10 scale – Except for field failure-100

19. Component Factors (continued) PAIN (continued) – Median value was found through integrating curve – From the area under the curve, the median PAIN and where it occurs in the process was found by locating the 50% point of the area – Median PAIN was 528 at numeric step number 2.67.

20. Determining Equation D*(.0189 (.155e 2.1692 X )*(0.4)y)*(0.182(z)) ____________________________________ *10 6 = PPM NEW T Where: D= # of parts found defective x= factor corresponding with step where defect is found y= factor corresponding with how complex each board is z= factor corresponding with how critical each defect is T=Throughput

21. Final Equation D*(.0029e 2.1692 X )*( 0.4 y )*( 0.182 z ) ___________________________________ *10 6 = PPM NEW T

22. DATA cube Once equation was finalized, will be put into a data cube The data cube has all of TYCO’s quality information needed to produce PPM NEW. The PPM NEW would be compared to PPM to determine overall impression of TYCO to validate equation

23. Future of Project Once the equation is ran through Data Cube, the equation can be validated Then it can be applied to all of PWB suppliers Moving Average will monitor suppliers Corrective Action can be taken

24. ABET Concerns Economic Concerns Ethical Concerns Social Concerns Political Concerns Sustainability

25. Any Questions ?