MPQ is the contribution of the manufacturing/assembly processes which causes the part/product to fail during production or first year of use. Failures caused during the first year of use are also known as infant mortality failures or early failures. MRMc gives insight in the expected failures and the failure frequency.
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 mflow or Value Stream Map. Based on this the lead time is determined.
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/assembly yield, test, rework and scrap the 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 materials added with the manufacturing/assembly contributions. When also the yield, test, rework and scap is taken into account a total carbon footprint is calculated based on the mflow or value Stream Map.
When designing and building complex machines in a market where the customer expections are high also the number of chalanges are high. Every company and market differs but the requirements of functionality, reliability and the industralization parameters as manufacturing quality, cost, build time and carbon footprint becomes difficult to ensure. When also the design and manufacturing takes place at different locations or even are outsourced the chalenge becomes even larger.
To get at least these industrialization issues under control a method/tool 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 . The largest contributors of the manufacturing quality, cost, building time and carbon footprint are idetified. Based on the TopX a mitigation can take place to avoid this from happening by mitigating those risks, time, cost or carbon footprint contributions by changing the design, adapting the supply chain or implemeting test strategies.
As a result of this method 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 industrilization is done after the design is finished a meager 10 -20% can be obtained in cost savings.
How to reach this a program is developed to secure the manufacturing quality, cost, building time or carbon footprint during the design phase.
First step is to set a clear expectation for the manufacturing quality, cost, building time and carbon footprint.
Second step is to predict the manufacturing quality, cost, building time or carbon footprint based on the design. Minimum requirement for this is the Bill of materials (BoM) and insight in the design.
Step three is to mitigate those items which causes the manufacturing quality, cost, building time or carbon footprint not reaching the expectations. For this a Top20 of the largest contributors is generated.
To do this analyses the prediction of the manafacturing quality, cost, build time and carbon footprint is automated. This is done 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 flow. The governing principle behind this is that every process which is being used to manufacturer the product is coupled to a part in the BoM. Based on the BoM/BoP list the parts and processes are completed with data containing the manufctauring risk, building time, part/process cost and the carbon footprint data. This results in a Value Stream Map (VSM) identifing all parts and processes which contribute most to the manufacturing quality, cost, building time or carbon footprint.
MRMc is to analyse the design based on the BoM and design files. How earlier this analysis is done the more impact it will have on the design and or supplier/supply chain decisions. With finished designs the resulting outcome is mostly more difficult to solve. The resulting output is an overview of the expected Cost, Building time and 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).