MPQ is the measure of how many product will fail during final assembly and first year of use at the customer caused by the manufacturing and assembly processes used to create the product. MRMc gives a quantitative insight in the to be expected failures of the product. The failure rate is derived from the Value Stream Map where for each part and process the failure rate, test slip and rework is being used.
Decisions made during the design phase will lead to manufacturing and assembly consequences. As a result together with the anticipated/selected supply chain the time to manufacture and build the product is calculated based on the Value Stream Map. Based on this the lead time is determined which highlights which path must be optimized for a minimum lead time.
Based on the manufacturing, assembly, part cost and supply chain uplifts this result in an ideal situation what a product should cost. Taking also into account the manufacturing and assembly failure rates, test slip, rework and scrap this will result is a more realistic insight of the product cost. Oprerational cost caused by the slipped through failures will add to the total cost of a product.
The product carbon footprint is based on the selected parts and the used materials added with the manufacturing and assembly contributions. When also the part and process failure rates , test slip, rework and scrap is taken into account a more realistic Carbon footprint is calculated based on the Value Stream Map.
When designing and building complex machines in a market where the customer expectations are high and the introduction time is limited the number of challenges are high. Every company, its products and market differs but the requirements of functionality, reliability and the industrialization parameters as manufacturing quality, cost, build time and carbon footprint must be ensured. When also the design and manufacturing takes place at different locations or even are outsourced the challenge to reach the product expectations becomes even larger.
To get at least these industrialization issues under control a Predictive Industrialization analysis is developed to visualize those issues upfront during the design phase. This method identifies the manufacturing quality, cost, building time, lead time and carbon footprint based on the expected supply chain before the design is released. Most issues are caused by decisions made during the design. With this Predictive Industrialization Analysis the largest contributors of the manufacturing quality, cost, building time and carbon footprint are identified. Based on the TopX an Industrialization mitigation can take place to avoid this from happening by mitigating those manufacturing risks, time, cost or carbon footprint contributions. This is done by first changing the design, adapting the supply chain, improving the manufacturing processes or implementing test strategies.
As a result of this Predictive Industrialization Analysis and mitigation the manufacturing quality is improved, cost is lower, building time shortened and carbon footprint optimized. The method, when used in the design phase, can deliver cost savings between the 20 and 40%. When the Predictive Industrialization Analysis and mitigation is done after the design is finished a meager 10 -20% can be obtained in cost savings.
How to reach this a Predictive Industrialization Analysis is developed to secure the manufacturing quality, cost, building time or carbon footprint during the design phase.
To do this predictive Industrialization Analyses of the part manufacturing quality, cost, build time and carbon footprint the analysis is automated. This is done by starting with a Bill of Material (BoM) of the product. Based on the BoM a Bill of Processes (BoP) can be generated out of the BoM resulting in a manufacturing or process flow (mflow). The BoM/BoP list of the parts and processes is completed with data containing the manufacturing risk, building time, part/process cost and the carbon footprint data. This results in a Value Stream Map (VSM) identifying all parts and processes which contribute most to the manufacturing quality, cost, building time or carbon footprint.
The consultancy follows the tree step program and advises on the expectation, folowed by a Predictive Industrialization analysis of the design based on the BoM and design files. Last step is based on the analysis mitigate the issues. How earlier this analysis is done the more impact it will have on the design and or supplier/supply chain decisions. The resulting output of the predictive Industrialization Analysis is an overview of the expected cost, building time, carbon footprint and the expected number of failures during the first year of use caused by the manufacturing processes. To help identifying the manufacturing caused failures, cost, building time and carbon footprint the four list are available with the most contributing parts and processes. All of this is visualized by a Value Stream Map (VSM).