Getting things made

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How to take a consumer electronics product from prototype to mass production

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  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Electrical appliances in stand-by cost £740 million and generate 4 million tonnes of CO2 in the UK alone every year
  • Getting things made

    1. 1. Energy Reducing Products Ltd Manufacturing Consulting Services September 2013
    2. 2. Introduction ERP manufacturing management services • There are many specialist steps required to take a product from prototype to mass production; • ERP has experience of these processes and has successfully taken a number of products into full production; • It makes sense to outsource this work as it is intermittent and specialist.
    3. 3. Manufacturer Communication It is Vital to communicate with manufacturers credibly • ERP has working relationships with many UK and Far Eastern product manufacturers • ERP has templates for – RFQs (Request for Quotation) – Manufacturing agreements – Licensing agreements – AQL agreements
    4. 4. Quotations and pricing negotiation Know the pitfalls • Use open book pricing agreement • Understand likely margins, wastage figures etc • Critical path to product delivery analysis and reduction • Ensure component multi-sourcing and/or • Carefully manage single source components
    5. 5. Use Open Book Pricing Create a win-win situation with the manufacturer • Create of Approved Vendor Lists • Create Bills of Materials including :– Source long lead time items quickly – MOQ's / batch size implications – Tooling / change costs • Establish the real capital outlay for initial and repeat orders
    6. 6. Manufacturing Execution Ensure execution is trouble free • Implement a Change Note system – ensure all changes are approved • Procedures for accepting alternative components • Manage alternative component sources • Ensure EN or UL approved components are used if and where necessary
    7. 7. Product delivery & Stock management Manage your cash and costs • Work with Sales teams to establish expected volumes • Use of waterfall or equivalent method to qualify these • Derive manufacturing finance requirements • Factoring to improve cash flow • Project repeat orders and advise manufacturer(s) • Manage long lead/critical components
    8. 8. Quality Assurance Work with manufacturer to ensure quality • Golden sample Acceptance • Implementation of AQL (Acceptable Quality Level) system • Ensure access to and knowledge of standard AQL tables • Test and acceptance of product batches • Critical, Major, Minor categorisation • Agreeing course of action on rejection
    9. 9. Test for Manufacture Maximise yield • Test software planning and delivery (before product release) • Manufacturing pack release requirements • Drafting of Functional Specifications, User Guides, etc • NB: PCB Pads for signal access
    10. 10. CE marks and European Approvals Meet regulatory requirements • ERP has access to British Standards Online • Can assist in choosing the correct standards • Safety Approval execution • EMC testing and approvals • CE Certificate generation • Relationships with specialist consultants in the UK / Far east
    11. 11. Parts List database creation The key to delivery • Knowledge of data field capture requirements • Part numbering systems to managing – Electrical / Electronic Components – Mechanical / non electrical Components – Assemblies and Components
    12. 12. Design for manufacture Make sure your product can be made in volume • Test for manufacture requirements • Bed of Nails Testing • Design and assembly of test rigs • Test-time adds to product cost, so design in fast test ability • IP protection, typically retain a key piece of technology ** ** Software only released in protected IC rather than in soft binary form
    13. 13. ERP Design Make sure it works and can be produced • ERP design consumer electronics products, providing – Consumer electronics software and hardware design – Schematic capture – PCB Layout (approvals may have impact) – Analogue and Digital hardware debug – Component tolerance analysis for acceptance
    14. 14. Relationships The ERP knowledge • Far Eastern manufacturers • UK manufacturers • UK Industrial Designers • UK low volume prototype assembly • Safety Approval consultants • EMC consultants • Component Distributors • Prototype plastics/product models
    15. 15. END Contact us Telephone: 01223 969934 Email: Giles.Hutchison@erp-uk.com

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