SMT Sales 2011


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SMT Sales 2011

  1. 1. Southern Manufacturing Technologies 2011
  2. 2. <ul><ul><li>Business Segments </li></ul></ul><ul><ul><ul><li>Aircraft </li></ul></ul></ul><ul><ul><ul><li>Aerospace </li></ul></ul></ul><ul><ul><ul><li>Defense </li></ul></ul></ul><ul><ul><ul><li>Commercial </li></ul></ul></ul><ul><ul><ul><li>Medical </li></ul></ul></ul><ul><ul><li>Location </li></ul></ul><ul><ul><ul><li>Tampa, FL </li></ul></ul></ul><ul><ul><ul><li>We have 90 employees </li></ul></ul></ul><ul><ul><li>Capacity 67% as of 12/31/10 </li></ul></ul>
  3. 3. <ul><ul><li>Customers </li></ul></ul><ul><ul><ul><li>AeroControlex </li></ul></ul></ul><ul><ul><ul><li>Conax (Cobham) </li></ul></ul></ul><ul><ul><ul><li>Honeywell </li></ul></ul></ul><ul><ul><ul><li>Teledyne </li></ul></ul></ul><ul><ul><ul><li>Triumph </li></ul></ul></ul><ul><ul><ul><li>Woodward </li></ul></ul></ul>
  4. 4. <ul><ul><li>Certifications </li></ul></ul><ul><ul><ul><li>AS 9100 </li></ul></ul></ul><ul><ul><ul><li>ISO 9001 </li></ul></ul></ul><ul><ul><li>Customers Certifications </li></ul></ul><ul><ul><ul><li>Honeywell – MPC (Manufacturing Process Control), Source Delegation </li></ul></ul></ul><ul><ul><ul><li>Triumph Actuation Systems – SIDA (Supplier Inspection Delegation Authority) </li></ul></ul></ul><ul><ul><ul><li>AeroControlex – ACES (AeroControlex Excellent Supplier) </li></ul></ul></ul>
  5. 5. <ul><ul><li>Visit for a virtual tour. </li></ul></ul>
  6. 6. <ul><ul><li>Materials </li></ul></ul><ul><ul><ul><li>Aluminum </li></ul></ul></ul><ul><ul><ul><li>Titanium </li></ul></ul></ul><ul><ul><ul><li>Stainless Steel </li></ul></ul></ul><ul><ul><ul><li>Inconel </li></ul></ul></ul><ul><ul><ul><li>Other metals </li></ul></ul></ul>Stainless Steel Satellite Valve Assembly Titanium Missile Defense Component Anodized Aluminum Servo Valve Housing Helicals Installed Aluminum Servo Valve Housings Anodized & Chem Filmed Helicals Installed Stainless Steel Parachute Release Assembly
  7. 7. Titanium Atomizer Bells Assembly Sectional View Aluminum Housing Multiple Hard Coat Surfaces Aluminum Deep Cover Hogout Anodized & Chem Filmed
  8. 8. Aluminum Cover Hogout Anodized & Chem Filmed Aluminum Cover Hogout Anodized & Chem Filmed Stainless Steel Rocket Valve Aluminum Housing Hogout Anodized & Chem Filmed
  9. 9. <ul><ul><li>In-House Processing </li></ul></ul><ul><ul><li>CNC Lathes with Live Tooling </li></ul></ul><ul><ul><li>CNC Mills Vertical / Horizontal with full 4 th axis and 5 th axis positioning </li></ul></ul><ul><ul><li>CNC Waterjet Deburring </li></ul></ul><ul><ul><li>Ballizing </li></ul></ul><ul><ul><li>Grinding </li></ul></ul><ul><ul><li>Manual mills, lathes, Bridgeports, etc. </li></ul></ul>
  10. 10. <ul><ul><li>Subcontract Processing </li></ul></ul><ul><ul><li>Blast / Shot Peen </li></ul></ul><ul><ul><li>Broach </li></ul></ul><ul><ul><li>EDM </li></ul></ul><ul><ul><li>Grind / Hone / Lap </li></ul></ul><ul><ul><li>Heat Treat </li></ul></ul><ul><ul><li>Laser Part Mark </li></ul></ul><ul><ul><li>Waterjet cutting </li></ul></ul><ul><ul><li>Subcontract Testing </li></ul></ul><ul><ul><li>FPI </li></ul></ul><ul><ul><li>MPI </li></ul></ul><ul><ul><li>X-Ray </li></ul></ul><ul><ul><li>Ultrasound </li></ul></ul><ul><ul><li>Pressure Test </li></ul></ul>
  11. 11. <ul><ul><li>In-House Surface Treatments </li></ul></ul><ul><ul><ul><li>Black Oxide </li></ul></ul></ul><ul><ul><ul><li>Chem Film </li></ul></ul></ul><ul><ul><li>Subcontracted Surface Treatments </li></ul></ul><ul><ul><ul><li>Anodize </li></ul></ul></ul><ul><ul><ul><li>Chem Film </li></ul></ul></ul><ul><ul><ul><li>Electropolish </li></ul></ul></ul><ul><ul><ul><li>Dry Lube / Dichronite </li></ul></ul></ul><ul><ul><ul><li>Paint </li></ul></ul></ul><ul><ul><ul><li>Passivate </li></ul></ul></ul><ul><ul><ul><li>Plating – Bronze, Chrome, Copper, Gold, Nickel, Black Nickel, Tin </li></ul></ul></ul><ul><ul><ul><li>Sermetel </li></ul></ul></ul>
  12. 12. <ul><ul><li>Collaborate with customers’ engineering depart ment </li></ul></ul><ul><ul><ul><li>Machine-ability </li></ul></ul></ul><ul><ul><ul><li>Cost saving opportunities </li></ul></ul></ul><ul><ul><ul><li>Understand customers’ true needs </li></ul></ul></ul><ul><ul><ul><li>Inspection techniques </li></ul></ul></ul><ul><ul><ul><li>Value-added options (assembly) </li></ul></ul></ul><ul><ul><li>Prototype </li></ul></ul><ul><ul><ul><li>One-off capability </li></ul></ul></ul><ul><ul><ul><li>On premise engineering </li></ul></ul></ul><ul><ul><ul><li>Specialized Tool Room </li></ul></ul></ul><ul><ul><li>Production Qualification </li></ul></ul><ul><ul><ul><li>Small production run(s) to prove out process </li></ul></ul></ul><ul><ul><li>Production </li></ul></ul><ul><ul><ul><li>Ramp up into full production </li></ul></ul></ul>
  13. 13. <ul><ul><li>New Part Team & Responsibilities: </li></ul></ul><ul><ul><li>Manufacturing Engineering </li></ul></ul><ul><ul><ul><li>Collaborate with customers’ engineers </li></ul></ul></ul><ul><ul><ul><li>Specify Raw Material Size & Shape </li></ul></ul></ul><ul><ul><ul><li>Process Planning & Routing </li></ul></ul></ul><ul><ul><ul><li>Operation Drawings </li></ul></ul></ul><ul><ul><ul><li>Fixture Drawings </li></ul></ul></ul><ul><ul><ul><li>Special Tool Drawings </li></ul></ul></ul><ul><ul><ul><li>CNC Programs </li></ul></ul></ul><ul><ul><ul><li>Tool Data Sheets </li></ul></ul></ul>
  14. 14. <ul><ul><li>New Part Team & Responsibilities: </li></ul></ul><ul><ul><li>Quality Engineering </li></ul></ul><ul><ul><ul><li>In-Process Inspection Forms </li></ul></ul></ul><ul><ul><ul><li>AS9102 FAIR </li></ul></ul></ul><ul><ul><ul><li>Review & Approve Operation Drawings </li></ul></ul></ul><ul><ul><ul><li>Gage Request Forms </li></ul></ul></ul><ul><ul><ul><li>Production Count Sheets </li></ul></ul></ul><ul><ul><ul><li>Define Special Gaging </li></ul></ul></ul>
  15. 15. <ul><ul><li>New Part Team & Responsibilities: </li></ul></ul><ul><ul><li>Purchasing </li></ul></ul><ul><ul><ul><li>Order Material </li></ul></ul></ul><ul><ul><ul><li>Locate New Suppliers as needed </li></ul></ul></ul><ul><ul><ul><ul><li>Use NADCAP & customer approved suppliers as required </li></ul></ul></ul></ul><ul><ul><ul><li>Expedite Special Tooling & Gaging </li></ul></ul></ul>
  16. 16. <ul><ul><li>New Part Team & Responsibilities: </li></ul></ul><ul><ul><li>CNC Supervisor </li></ul></ul><ul><ul><ul><li>Collaborate with Manufacturing Engineers </li></ul></ul></ul><ul><ul><ul><li>Recommend Work Centers </li></ul></ul></ul><ul><ul><ul><li>Coordinate with other Key Personnel </li></ul></ul></ul>
  17. 17. <ul><ul><li>New Part Team Summary: </li></ul></ul><ul><ul><li>New part team typically meets 2 – 5 times during the new part development process. </li></ul></ul><ul><ul><li>Team credentials: </li></ul></ul><ul><ul><li>Black Belt </li></ul></ul><ul><ul><li>Green Belts </li></ul></ul><ul><ul><li>NIMS Certified Senior Trainer </li></ul></ul><ul><ul><li>NIMS OJT Trainers </li></ul></ul><ul><ul><li>Certified Project Manager </li></ul></ul>
  18. 18. <ul><ul><li>Day (-32) RFQ Received </li></ul></ul><ul><ul><li>Day (-25) Completed Quote Sent to Customer </li></ul></ul><ul><ul><li>Day 1 PO Received </li></ul></ul><ul><ul><li>Day 3 Meeting 1 – New Part Team </li></ul></ul><ul><ul><li>Day 9 Raw Material Ordered </li></ul></ul><ul><ul><li>Day 12 Meeting 2 – New Part Team </li></ul></ul><ul><ul><li>Day 15 Raw Material Received </li></ul></ul><ul><ul><li>Day 28 Meeting 3 – New Part Team – Process Released </li></ul></ul><ul><ul><li>Day 36 Production Start </li></ul></ul><ul><ul><li>Day 36-65 Internal Processing </li></ul></ul><ul><ul><li>Day 65-68 Outside Processing </li></ul></ul><ul><ul><li>Day 69 Final Internal Processing </li></ul></ul><ul><ul><li>Day 70 FAIR </li></ul></ul><ul><ul><li>Day 73 Source Inspection & Ship </li></ul></ul>2 revision changes received before production start
  19. 19. <ul><ul><li>New Part Summary </li></ul></ul><ul><ul><li>Part quoted with a 12 week lead time and delivered in less than 11 weeks. </li></ul></ul><ul><ul><li>“ 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 work with.  The parts you dropped off Monday look great, and our quality engineer who performed First Article Inspection commented on the quality of the part and your facility.  It is not every day that a vendor provides a quality product  and delivers a full week ahead of schedule.  I am looking forward to working with SMT in the future and I just wanted to thank you for all your hard work.” </li></ul></ul><ul><ul><li>Many things, including, complexity, number and types of outside processes, and revision changes, influence the lead time and responsiveness. </li></ul></ul>
  20. 20. “ As I walked through the facility it was obvious there is a high level of value placed on the employees of SMT. The facility was very clean, organized, with machines strategically located, all good indicators of a committed and dedicated work team. There was also evidence of a strong emphasis on lean manufacturing practices which supports effective cost reduction opportunities. Also obvious was the commitment to stay current with the latest machining capabilities. The machines are modern, appeared to be well maintained and strategically located to support the lean concept and most important, an AS9001 quality system. The installation of the water jet deburr machine is a significant addition to the overall operation. In today’s supply chain environment where reduction and consolidation are the norm, first impressions are more important then ever and SMT shows well. As a participant of the Goodrich Corporation Interiors machining team I will include your company as a potential machining supplier to all Interiors sites of Goodrich, domestic and internationally. My applause to SMT’s President, Roy Sweatman for successfully leading his company through these rough economic times and for preparing SMT for continued growth and success.” Letter from 27 yr supply chain professional after tour of Southern Manufacturing Technologies, December 2010. Letter from Goodrich buyer, 12/2010
  21. 21. <ul><ul><ul><li>Lights out machining </li></ul></ul></ul><ul><ul><ul><li>3 Horizontal Mills with twin pallets </li></ul></ul></ul><ul><ul><ul><ul><li>2 machines with 300 tool magazine </li></ul></ul></ul></ul><ul><ul><ul><ul><li>1 machine with 120 tool magazine </li></ul></ul></ul></ul><ul><ul><ul><li>2 load stations </li></ul></ul></ul><ul><ul><ul><li>23 pallets </li></ul></ul></ul><ul><ul><ul><li>Runs 24/7 </li></ul></ul></ul>
  22. 22. <ul><ul><ul><li>Unidirectional press </li></ul></ul></ul><ul><ul><ul><li>Carbide ball </li></ul></ul></ul><ul><ul><ul><li>Customized fixtures </li></ul></ul></ul><ul><ul><ul><li>Dimensional accuracy </li></ul></ul></ul><ul><ul><ul><li>11 sigma process </li></ul></ul></ul><ul><ul><ul><li>Surface finish </li></ul></ul></ul>
  23. 23. <ul><ul><li>Purpose </li></ul></ul><ul><ul><ul><li>Quality </li></ul></ul></ul><ul><ul><ul><li>Consistency </li></ul></ul></ul><ul><ul><ul><li>Reliability </li></ul></ul></ul><ul><ul><ul><li>Efficiency </li></ul></ul></ul><ul><ul><ul><li>Cost Savings </li></ul></ul></ul>KAN KH-6 Waterjet Deburring Center
  24. 24. <ul><ul><li>New tooling added to Horizontal Mills </li></ul></ul>External burrs Internal burrs
  25. 25. <ul><ul><li>Kan KH-6 Waterjet Deburr Machine </li></ul></ul><ul><li>B Axis rotary table with 0°-90° tilt angle. </li></ul><ul><li>View from service door </li></ul><ul><li>Arms and Tips with X Y Z movement. </li></ul><ul><li>View from service door </li></ul>Static Nozzle Rotary Nozzle Air Nozzle x y z b 0°-90°
  26. 26. <ul><ul><li>Fixtures & Work Holding </li></ul></ul>Part fixtures are designed in house for load and unload on the machine master pallets. A magnetic sensor system recognizes the pin configuration, identifying the part being processed, and loads the correct CNC program. Master pallet Work hold fixture Pin config Master pallet Work hold fixture Pin config B=0° B=90° B=180° B=270° b 0°-90°
  27. 27. <ul><li>Rotary nozzle </li></ul><ul><ul><li>Used for internal deburring. </li></ul></ul><ul><ul><li>Comes with 7 Speed settings (200 to 900 rpm) </li></ul></ul><ul><li>Static nozzle </li></ul><ul><ul><li>Used for washing cycles. </li></ul></ul><ul><li>Air nozzle </li></ul><ul><ul><li>Used for blowing cycles. </li></ul></ul><ul><ul><li>Nozzles </li></ul></ul>
  28. 28. <ul><ul><li>Before & After </li></ul></ul>
  29. 29. <ul><ul><li>Tool Paths Used </li></ul></ul><ul><li>Helical X Y Z movement </li></ul><ul><ul><li>Using a custom macro </li></ul></ul><ul><li>Z step movement </li></ul><ul><ul><li>Using a custom macro </li></ul></ul><ul><li>Contour X Y Z movement </li></ul><ul><ul><li>Using Esprit CAD/CAM </li></ul></ul>
  30. 30. Before implementation After implementation Final product
  31. 31. <ul><ul><li>Example: Complex Housing </li></ul></ul>Machine Time Waterjet Manual Deburr Before Implementation 1.24 Hr/pt 0 2.2 Hr/pt After Implementation 1.34 Hr/pt 13 min/pt 54 min/pt 41% Total Improvement -8% improvement 49 % improvement
  32. 32. <ul><ul><li>Long-Term Agreements </li></ul></ul><ul><ul><ul><li>Build to Forecasts </li></ul></ul></ul><ul><ul><ul><li>Build to SOI (Supplier Owned Inventory) </li></ul></ul></ul><ul><ul><ul><li>Build to VMI (Vendor Managed Inventory) </li></ul></ul></ul><ul><ul><ul><li>Build to Kanban </li></ul></ul></ul><ul><ul><ul><li>JIT (Just In Time) Delivery </li></ul></ul></ul><ul><ul><ul><li>NP Agreements </li></ul></ul></ul>
  33. 33. Awards won in 2010 by SMT <ul><ul><ul><li>2010 NTMA Technology Award Winner </li></ul></ul></ul><ul><ul><ul><li>SHARP Award Winner, OSHA </li></ul></ul></ul>
  34. 34. <ul><ul><ul><li>Questions? </li></ul></ul></ul>