Southern Manufacturing Technologies              2013
Business Segments    • Aircraft    • Aerospace    • Defense    • Commercial    • MedicalLocation    • Tampa, FL    • We ha...
Customers   •   AeroControlex   •   Conax (Cobham)   •   Honeywell   •   Teledyne   •   Triumph   •   Woodward
Certifications    • AS 9100    • ISO 9001   Customers Certifications   • Honeywell – MPC (Manufacturing Process Control), ...
Visit www.smt-tampa.com for a virtual tour.
Materials   • Aluminum   • Titanium   • Stainless Steel   • Inconel                    Anodized Aluminum          Aluminum...
Aluminum HousingTitanium Atomizer Bells                           Multiple Hard Coat SurfacesAssembly Sectional View   Alu...
Aluminum Cover Hogout          Aluminum Cover HogoutAnodized & Chem Filmed         Anodized & Chem FilmedStainless Steel R...
In-House Processing• CNC Lathes with Live Tooling• CNC Mills Vertical / Horizontal with full 4th axis and 5th axis   posit...
Subcontract Processing• Blast / Shot Peen• Broach• EDM• Grind / Hone / Lap• Heat Treat• Laser Part Mark• Waterjet cuttingS...
In-House Surface Treatments    • Black Oxide    • Chem FilmSubcontracted Surface Treatments   • Anodize   • Chem Film   • ...
Collaborate with customers’ engineering depart ment   • Machine-ability   • Cost saving opportunities   • Understand custo...
New Part Team & Responsibilities:Manufacturing Engineering  • Collaborate with customers’ engineers  • Specify Raw Materia...
New Part Team & Responsibilities:Quality Engineering  • In-Process Inspection Forms  • AS9102 FAIR  • Review & Approve Ope...
New Part Team & Responsibilities:Purchasing   • Order Material   • Locate New Suppliers as needed      • Use NADCAP & cust...
New Part Team & Responsibilities:CNC   Supervisor  •   Collaborate with Manufacturing Engineers  •   Recommend Work Center...
New Part Team Summary:New part team typically meets 2 – 5 times during the new part  development process.Team credentials:...
Day (-32)   RFQ ReceivedDay (-25)   Completed Quote Sent to CustomerDay 1       PO ReceivedDay 3       Meeting 1 – New Par...
New Part SummaryPart quoted with a 12 week lead time and delivered in less than11 weeks.“It has been a pleasure working wi...
Letter from Goodrich buyer, 12/2010“As I walked through the facility it was obvious there is a high level of value placed ...
•   Lights out machining•   3 Horizontal Mills with twin pallets     • 2 machines with 300 tool magazine     • 1 machine w...
•   Unidirectional press•   Carbide ball•   Customized fixtures•   Dimensional accuracy•   11 sigma process•   Surface fin...
Purpose  • Quality  • Consistency  • Reliability  • Efficiency     KAN KH-6 Waterjet Deburring Center  • Cost Savings
New tooling added to Horizontal MillsExternal burrs  www.harveytool.comInternal burrs   www.jwdone.com
Kan KH-6 Waterjet Deburr Machine         b0°-90°                                          v B Axis rotary table with 0°-90...
Fixtures & Work HoldingMasterpallet   Work hold                        Part fixtures are designed in house for load       ...
Nozzlesv Rotary nozzle   • Used for internal deburring.   • Comes with 7 Speed settings (200 to     900 rpm)v Static nozzl...
Before & After
Tool Paths Used    A. Helical X Y Z movement        • Using a custom macro    A. Z step movement        • Using a custom m...
Before implementation   After implementation   Final product
Example: Complex Housing                 Machine Time      Waterjet          Manual Deburr    Before                    1....
Long-Term Agreements   • Build to Forecasts   • Build to SOI (Supplier Owned Inventory)   • Build to VMI (Vendor Managed I...
Awards won in 2010 by SMT2010 NTMA Technology Award Winner   SHARP Award Winner, OSHA
Questions?
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SMT 2013

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SMT 2013

  1. 1. Southern Manufacturing Technologies 2013
  2. 2. Business Segments • Aircraft • Aerospace • Defense • Commercial • MedicalLocation • Tampa, FL • We have 110 employeesCapacity 90% as of 12/31/12
  3. 3. Customers • AeroControlex • Conax (Cobham) • Honeywell • Teledyne • Triumph • Woodward
  4. 4. Certifications • AS 9100 • ISO 9001 Customers Certifications • Honeywell – MPC (Manufacturing Process Control), Source Delegation • Triumph Actuation Systems – SIDA (Supplier Inspection Delegation Authority) • AeroControlex – ACES (AeroControlex Excellent Supplier)
  5. 5. Visit www.smt-tampa.com for a virtual tour.
  6. 6. Materials • Aluminum • Titanium • Stainless Steel • Inconel Anodized Aluminum Aluminum Servo Valve Housings • Other metals Servo Valve Housing Helicals Installed Anodized & Chem Filmed Helicals Installed Titanium Missile Defense Stainless Steel Satellite Stainless Steel Component Valve Assembly Parachute Release Assembly
  7. 7. Aluminum HousingTitanium Atomizer Bells Multiple Hard Coat SurfacesAssembly Sectional View Aluminum Deep Cover Hogout Anodized & Chem Filmed
  8. 8. Aluminum Cover Hogout Aluminum Cover HogoutAnodized & Chem Filmed Anodized & Chem FilmedStainless Steel Rocket Valve Aluminum Housing Hogout Anodized & Chem Filmed
  9. 9. In-House Processing• CNC Lathes with Live Tooling• CNC Mills Vertical / Horizontal with full 4th axis and 5th axis positioning• CNC Waterjet Deburring• Ballizing• Grinding• Manual mills, lathes, Bridgeports, etc.
  10. 10. Subcontract Processing• Blast / Shot Peen• Broach• EDM• Grind / Hone / Lap• Heat Treat• Laser Part Mark• Waterjet cuttingSubcontract Testing• FPI• MPI• X-Ray• Ultrasound• Pressure Test
  11. 11. In-House Surface Treatments • Black Oxide • Chem FilmSubcontracted Surface Treatments • Anodize • Chem Film • Electropolish • Dry Lube / Dichronite • Paint • Passivate • Plating – Bronze, Chrome, Copper, Gold, Nickel, Black Nickel, Tin • Sermetel
  12. 12. Collaborate with customers’ engineering depart ment • Machine-ability • Cost saving opportunities • Understand customers’ true needs • Inspection techniques • Value-added options (assembly)Prototype • One-off capability • On premise engineering • Specialized Tool RoomProduction Qualification • Small production run(s) to prove out processProduction • Ramp up into full production
  13. 13. New Part Team & Responsibilities:Manufacturing Engineering • Collaborate with customers’ engineers • Specify Raw Material Size & Shape • Process Planning & Routing • Operation Drawings • Fixture Drawings • Special Tool Drawings • CNC Programs • Tool Data Sheets
  14. 14. New Part Team & Responsibilities:Quality Engineering • In-Process Inspection Forms • AS9102 FAIR • Review & Approve Operation Drawings • Gage Request Forms • Production Count Sheets • Define Special Gaging
  15. 15. New Part Team & Responsibilities:Purchasing • Order Material • Locate New Suppliers as needed • Use NADCAP & customer approved suppliers as required • Expedite Special Tooling & Gaging
  16. 16. New Part Team & Responsibilities:CNC Supervisor • Collaborate with Manufacturing Engineers • Recommend Work Centers • Coordinate with other Key Personnel
  17. 17. New Part Team Summary:New part team typically meets 2 – 5 times during the new part development process.Team credentials:• Black Belt• Green Belts• NIMS Certified Senior Trainer• NIMS OJT Trainers• Certified Project Manager
  18. 18. Day (-32) RFQ ReceivedDay (-25) Completed Quote Sent to CustomerDay 1 PO ReceivedDay 3 Meeting 1 – New Part TeamDay 9 Raw Material OrderedDay 12 Meeting 2 – New Part TeamDay 15 Raw Material ReceivedDay 28 Meeting 3 – New Part Team – Process ReleasedDay 36 Production StartDay 36-65 Internal ProcessingDay 65-68 Outside ProcessingDay 69 Final Internal ProcessingDay 70 FAIRDay 73 Source Inspection & Ship 2 revision changes received before production start
  19. 19. New Part SummaryPart quoted with a 12 week lead time and delivered in less than11 weeks.“It has been a pleasure working with SMT throughout the entire procuring process.From the beginning you and your team were very responsive and very easy to workwith. The parts you dropped off Monday look great, and our quality engineer whoperformed First Article Inspection commented on the quality of the part and yourfacility. It is not every day that a vendor provides a quality product and delivers a fullweek ahead of schedule. I am looking forward to working with SMT in the future and Ijust wanted to thank you for all your hard work.”Many things, including, complexity, number and types of outsideprocesses, and revision changes, influence the lead time andresponsiveness.
  20. 20. Letter from Goodrich buyer, 12/2010“As I walked through the facility it was obvious there is a high level of value placed on the employees ofSMT. The facility was very clean, organized, with machines strategically located, all good indicators of acommitted and dedicated work team. There was also evidence of a strong emphasis on lean manufacturingpractices which supports effective cost reduction opportunities.Also obvious was the commitment to stay current with the latest machining capabilities. The machines aremodern, appeared to be well maintained and strategically located to support the lean concept and mostimportant, an AS9001 quality system. The installation of the water jet deburr machine is a significantaddition to the overall operation.In today’s supply chain environment where reduction and consolidation are the norm, first impressions aremore important then ever and SMT shows well. As a participant of the Goodrich Corporation Interiorsmachining team I will include your company as a potential machining supplier to all Interiors sites ofGoodrich, domestic and internationally.My applause to SMT’s President, Roy Sweatman for successfully leading his company through these rougheconomic times and for preparing SMT for continued growth and success.”Letter from 27 yr supply chain professional after tour of Southern Manufacturing Technologies, December2010.
  21. 21. • Lights out machining• 3 Horizontal Mills with twin pallets • 2 machines with 300 tool magazine • 1 machine with 120 tool magazine• 2 load stations• 23 pallets• Runs 24/7
  22. 22. • Unidirectional press• Carbide ball• Customized fixtures• Dimensional accuracy• 11 sigma process• Surface finish
  23. 23. Purpose • Quality • Consistency • Reliability • Efficiency KAN KH-6 Waterjet Deburring Center • Cost Savings
  24. 24. New tooling added to Horizontal MillsExternal burrs www.harveytool.comInternal burrs www.jwdone.com
  25. 25. Kan KH-6 Waterjet Deburr Machine b0°-90° v B Axis rotary table with 0°-90° tilt angle. View from service door y xz Rotary Nozzle v Arms and Tips with X Y Z movement.Static Nozzle View from service door Air Nozzle
  26. 26. Fixtures & Work HoldingMasterpallet Work hold Part fixtures are designed in house for load fixture and unload on the machine master pallets. A magnetic sensor system recognizes the pin configuration, identifying the part being Pin config processed, and loads the correct CNCMaster Work hold program.pallet fixture b B=270° B=180° 0°-90° Pin config B=0° B=90°
  27. 27. Nozzlesv Rotary nozzle • Used for internal deburring. • Comes with 7 Speed settings (200 to 900 rpm)v Static nozzle • Used for washing cycles.v Air nozzle • Used for blowing cycles.
  28. 28. Before & After
  29. 29. Tool Paths Used A. Helical X Y Z movement • Using a custom macro A. Z step movement • Using a custom macro C. Contour X Y Z movement • Using Esprit CAD/CAM
  30. 30. Before implementation After implementation Final product
  31. 31. Example: Complex Housing Machine Time Waterjet Manual Deburr Before 1.24 Hr/pt 0 2.2 Hr/ptImplementation After 1.34 Hr/pt 13 min/pt 54 min/ptImplementation 41% Total -8% improvement 49 % improvement Improvement
  32. 32. Long-Term Agreements • Build to Forecasts • Build to SOI (Supplier Owned Inventory) • Build to VMI (Vendor Managed Inventory) • Build to Kanban • JIT (Just In Time) Delivery • NP Agreements
  33. 33. Awards won in 2010 by SMT2010 NTMA Technology Award Winner SHARP Award Winner, OSHA
  34. 34. Questions?

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