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A Strategy to Improve Design Quality, Reduce Costs and
Shorten Time to Market
Presentation date: 24-Oct-2017Presenter Name: Nitin PrayagRoom name: Room 1 (Foyer Hall)Structured approach to Design for eXcellence using DFMPro in NX
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HCL Overview along with ERS Line of Business Snapshot
$7.2B
120,000EMPLOYEES
32COUNTRIES
ENGINEERING and R&D SERVICES
A $1.4 Bn+ UNIT UNDER HCL TECH
Top 3 Global Engineering Services Company
40+ Years of Complex Engineering Experience
24,000+ Engineers
55 of Top 100 Global R&D Companies as Customers
100+ Client Development Centers and 110+ Customer - Specific Labs
1,250+ Patents Filed for Customers
$25M+ Worth Investments in Laboratory Facilities
Ae
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& D
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Au
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Tele
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Tele
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Net
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Sto
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Co
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Ind
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Mfg
Sem
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Off
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Au
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ISV
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FPGA, ASIC and SOC Design
Embedded Systems
Hardware & System Design
Mechanical Design
Product QA and V&V
GeometricPLM
Software Product and Platform Engineering
HCL Enterprise
IN REVENUE
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References from Around the World Indicate the Huge Cost and Effort Impact Associated with Engineering Change Orders
ECOs consume one third to one half of engineering capacity –Soderberg, L.G. , Facing
up to the engineering Gap. McKinsey Quarterly
ECOs represent 20 to 50% of tool costs (around 100M USD in large projects)
– Lincke, W. Simultaneous Engineering
30% of all work effort was due to engineering changes… – Fricke et al
A study of over 2,000 ECOs created over the course of three months at an industrial equipment manufacturing company has shown that DFX Issues contribute to around 70% of engineering change orders.
These DFX issues fall in the “preventable” category
Average number of ECOs in aerospace could be around 1500-2000 per program per year - In total, the number of ECOs could
exceed 5000 per year
Approximately 4-5% of the Engineering Change Orders are linked to non-adherence of Design/Manufacturing/ Assembly rules
Average ECO cost could be as high as 25000-50000 USD across the development lifecycle
Basic Idea, Concept, Evaluation Phase
Test design
Release design to manufacturing
The factory begins to fabricate
Detailed design
Build design
Current design inproduction
Time
The typical cost of design change
Cost of change in US $(As an example in automotive industry the average value ofx = 4K - 6K per change)
Approximately 80 x
100 x
10 x
x
The typical number of design changes
SHIFT THE MOUNTAIN
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To Consider all Aspects of Product Designs, Designers should Take the Holistic Approach
Is the thread engagement sufficient for the joint?
Is the required clearance maintained between the parts?
Is the fastener accessible for serviceability?
Can this fillet radius be achieved through the casting process?
Is the hole aligned properly?
Is the correct draft angle applied?
Is uniform wall thickness maintained?
Can this contact area lead to corrosion because of incompatible materials?
Quality
Environment
Reliability
Manufacturing
Service
Assembly
Manufacturing
Assembly
DFX
Design for Assembly
Design for Service
Design for Procurement
Design for Manufacture
Design for Costing
Design for Reliability
Design for Environment
Design for Reuse
Design for Commonality
Design for Disassembly
Design for Safety
Design For eXcellence (DFX) consists of methods, guidelines, standards and checks for creating better products focused on providing benefits in multiple stages of the product lifecycle
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3D Model
Manufacturability report
DFMPro NX
Manufacturability and Cost drivers
Optimized design
ReadyFor Manufacturing
Design
SourcingSupplier
Capability
GlobalBest practices
Input OutputCreate
Modify
Competency
Knowledge Capture
Elements of cost
Manufacturing Service
DFMPro for NX Solution
Knowledge Database
DFMPro Enables Organizations to Take Frontload Decisions…
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and Comes with Built in Checks for Standard Manufacturing Processes
Injection Molding Sheet MetalMachining
CastingAssembly Additive Manufacturing
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Fastener Accessibility
To ensure ease of assembly and maintenance, clear access for
fastening tool has to be provided
ProducibilityServiceability
Rate of productionEase of service
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Fastener Clearance
To ensure ease of assembly and error-free operation, sufficient axial and radial
clearance for a fastener should be provided
Clearance beyond bolt projection
Radial Clearance
Axial Clearance for a Screw
Screw
Insert
Boss
QualityBest Practices
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Sharp Internal Corner
Sharp inside corners require expensive and machining methods like EDM
ProducibilityCost
QualityRate of Production
Tooling Cost
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Deep Radiused Corners
Deep radiused corners require longer end mills prone to breakage, chatter and requiring longer machining times.
QualityCost
Best PracticesTooling Cost
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Preferred Holes Size
Standard and uniform drill sizes are preferred to avoid extra tooling and setup time. Ultimately it will reduce cost of manufacturing and reduces cycle time.
ProducibilityRate of Production
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Knife Edge
Knife/sharp edges should be avoided for ensuring safety and promote ease of handling, eliminating additional operations cost and preventing fatigue failures
QualitySafety
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Three Steps for Successful DFX Deployment for Your Organization
• Define Key priorities for your organization- Time to market, reduce Engineering Changes, improve quality, improve Engineering productivity
• Set up a DFX organization and identify DFX champion
• Identify key rules for business benefits
• Identified key location for deployment
• Configure OOTB DFMPro+Checkmatefor validation based on company standards
• Feedback from various stakeholders on downstream DFX requirements
• Convert DFX requirements to rules for development in DFMPro
• Roll-out, installation, training, customization
• Weekly DFX meetings to track the usage and address key issues
ENTERPRISE DEPLOYMENT
• Deploy DFMPro+Checkmate for all target users
• All locations
• Standard and custom rules covering organizational knowledge base
• Set up a process to ensure continuous knowledge capture & implementation of specific rules
• Continuous improvement by building new rules to avoid occurring Engineering changes and quality issues
• Monthly DFX meeting to track the usage, benefits and new improvements required.
Step 1 -
Define Priorities for your Company
Step 2 -
Pilot deployment
Step 3 -
REALIZATION OF BENEFITS
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Designer
SupplierCapability
GlobalBest practices
Competency
Knowledge database
Create Modify
Continues improvement
Closed Loop Quality Feedback Implementation to Avoid Reoccurrence of Changes Related to Quality and Design
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NX Design Validation –DFMPro & Check-Mate
NX Unified Design Validation Framework
NX
De
sign
Val
idat
ion
Modeling Standards
Features
Geometry
Drawings, Sketches
PMI checks
File Structure
Modeling practices
Customer specific checks
Manufacturability
Drilling
Milling
Turning
Casting
Injection Molding
Assembly
Standardization
Standard tools
Tolerances
Standard components
Customer Mfg standards Customer Specific rules
DFM
Pro
fo
r N
XC
he
ck-M
ate
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Results in Teamcenter
How do DFMPro+Check-Mate results work with Teamcenter?
• DFMPro+Check-Mate can use the Validation Manager
application within Teamcenter to store and manage its
results
• DFMPro+Check-Mate results for a part are stored in a
Validation Master Form under the item revision
• Each check (or profile) is marked as out-of-date or pass/fail
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Benefits from Implementing DFX Solution
Hard Savings Soft Savings
Standardization across different R&D locations
1. Features2. Drawings3. Materials4. Design Procedures and processes
Overall improvement in Product quality and capability of the tool to predict and arrest all design related quality issues for NPD
Cost savings from reduced number of ECO’s Improved First time right time to market due to savings in reduced EC’s
Savings from improvement in Engineering productivity
Capture knowledge within organization including supplier’s capability
Reduced Tooling costs and warranty costs Time savings from collaboration between teams and suppliers
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Thank You
www.dfmpro.com | For queries [email protected]
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Motivation
Reduced Engineering Changes
Design Quality Improvement
Knowledge Capture
Key focus Description Customer Impact
Reduced engineering rework, more time and focus for core R&D activities
Help to meet aggressive schedules in demanding environment with improved efficiency
Reduction in turn-backs from downstream to design
Reduction in downtime/delays in downstream functions. Overall reduction in rework costs
Improved mechanism to capture knowledge in a system
Capture knowledge from Ageing workforce and mitigate risk, improve competency of new engineers
Improving Time to Market
Ship products faster to market compared to competition
Savings in opportunity cost
Reducing Product Costs
Improve standardization and manufacturing time thus reducing the cost of the product
Improved control on effective pricing/higher profits due to lower product costs