Client Testimonial:

"We were on a very aggressive development schedule that required the set-up of a clean room assembly process for a new electro-mechanical product. D&K Engineering brought in the entire compliment of engineering capability to establish an efficient manufacturing process. The expertise, professionalism and project management skills brought to the project allowed me to concentrate on other responsibilities."

Project Manager
Manufacturing Process, Tool, and Line Development

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Client Need:

Client needed firm able to:

  • Assemble and supply prototype consumer product
  • Design and fabricate assembly equipment to facilitate this process
  • Meet the projected sales ramp (650/day peak) while developing and refining the manufacturing processes
  • Implement SPC into the manufacturing of the product
  • Do the above with the intention of eventual off/near shore production

D&K Solution:

D&K performed all of the following:

  • Utilized D&K's lab with a localized class 10,000 clean-room environment
  • Designed and fabricated an array of prototype tooling equipment (pneumatics, electronics, controls, jigs, fixtures, actuators, sensors...etc)
  • Performed DOE's to establish and improve assembly procedures and processes
  • Developed a manufacturing model to predict tooling and operator requirements for various volumes, yields, cycle times and downtimes
  • Designed semiautomatic tools for production environment
  • Modeled the factory floor to quickly simulate alternatives
  • Selected appropriate SPC system
  • Manufactured high quality prototypes on an ongoing basis (20-30 units per month)

Results:

A manufacturing model was developed to simulate various manufacturing scenarios. Over a dozen semiautomatic tools were designed and implemented on the line. Real time Control Charts were used for immediate manufacturing decisions and database queries were used for helping to solve latent design, material or workmanship issues.

Client was delighted with results and engaged with D&K in design and implementation of production processes. Co-developed high level program plan, key milestones, budgets and overall manufacturing strategy for consumer product.