International Appliance Manufacturing 2008 - (Page 7) Example 1: Early-phase optimisation The major functional and cosmetic component shown left has many thin sections that will generate recurring quality issues in production: issues that, with detailed analysis early in the process, can be corrected and optimised through design improvement and mould tool optimisation. possible to reduce, or even remove entirely, some of these costs. Not only can we provide engineers with far greater certainty in terms of production outcome. This early-stage strategy also provides planners, product managers and CFOs with accurate, comprehensive insights into the actual – and avoidable – costs of product and process development. (MPI) and Siemens NX, Pro/E, Catia and AutoCad design suites, was originally conceived to enable Rosti’s engineering teams to integrate seamlessly with customer teams globally. Early-phase optimisation See Example 1. above. If this inherent design flaw is allowed to enter into production, it will lead to sub-standard moulding and could typically add 15% to cycle times due to higher material temperatures. Compounded, costs will accumulate as follows: • Higher machine overheads to pay for lost productive capacity, which impacts depreciation and facility costs. • Higher operating overheads to manage smaller processing windows, which will impact the cost of quality and add the cost of attending to critical machine (m/c) parameters. • Higher total business overhead resulting from unnecessary capital investment and finance costs. Yet a business that applies Design for Manufacture disciplines rigorously will, over time, generate typically 15% more output without additional investment. When this is combined with savings in direct expenses - a significant competitive advantage is created, and one that should be factored into the manufacturers technology road map. This is a fundamental question for the major appliance brands. When addressing competitiveness and selecting manufacturing partners, OEMs should be querying whether their manufacturers have the resources to participate fully in the development process. Are they equipped and do they have the skills to optimise product at the product creation stage? Because if they do not, the brand is foregoing competitive advantage. See Example 2. (shown over the page). While this is not an appliance component system, it is a very advanced ‘Metal to Plastic’ Conversion, which demonstrates an assembly that is under high stress in service and must be geometrically stable from the Software technologies for improved performance Rosti has established a toolbox of state-of-the-art product and process development software with a value of more than $430,000: a toolbox that is regarded as business critical to successfully filling the gap between conventional moulders and giant contract manufacturers – and living up to the term ‘solution provider’. Rosti’s ‘product creation’ portfolio of business systems and engineering software, which includes Ansys Finite Element Analysis, Moldflow Part Adviser (MPA), Moldflow Plastics Insight International Appliance Manufacturing 2008 7
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