Automotive molds - BSM Group (Shenzhen)
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Transcript of Automotive molds - BSM Group (Shenzhen)
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BSM AND ?????
December 9th 2013
BSM Company Overview
BSM Group, Global
Bluestar Mould Staff??????Managing Director, Owner
???????? Business Director
???????Engineering Director
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Bluestar Review
Focus on the customer
1Company Overview 2Capabilities
3Future
Planning
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Company Overview> Locations> Markets>Turnover>Organization and Management>Global Network
BSM 2013
1
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Mar
kets
and
Tur
nove
r “A” Main Factory 20,000 ㎡ in Baoan,
Shenzhen (45 minute drive from Shekou to Baoan)
“B” Corporate Headquarters, Technology Building, Shekou, Shenzhen
“C” Hong Kong Airport (40 minute ferry ride to Shekou)
A
B
C
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Mar
kets
and
Tur
nove
r550 employees, With Engineers in America and Mexico
Revenue Split
Product Destination15% delivered to China30% delivered to Europe30% delivered to North America25% delivered to Japan /Australia /Others
2007 2008 2009 2010 2011 2012 2013(Forcast)
0
10
20
30
40
50
60
70
33 3530
40
5560
70Turnover (in USD million)
Appli-ance; 8%
Automotive; 75%
Electron-ics; 5%
Health-care,
Medical/Dental;
6%
Indus-trial; 3%
Other; 3%
Industry Breakdown
Tooling 65% Molding 35%
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BSM
Org
aniz
ation
and
M
anag
emen
t
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Glo
bal N
etw
ork,
aft
er s
ales
se
rvic
e, E
ngin
eerin
g, S
ales
After sales service center
Technical and customer service office
Ontario, Canada
New York, USA
Arizona, USA
Alagoas, Brazil
Gunma, Japan
Shenzhen,
China
Slavkov, CzechParis, France London, UK
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2 Capabilities>Research and Development>Engineering and Analysis >Tooling>Molding>Secondary Operations>Quality
R&D to Production
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Rese
arch
and
Dev
elop
men
t
19 R&D staff mainly engaged in auto components, body parts, internal and external products research, design and development.
Cooperate with Guangdong Mold Association and Automobile Research Institute in South China University of Technology.
200 square meters of laboratory space area, with various kinds of testing equipment for optics, materials, environment, mechanics, etc, which can meet different kinds of tests like product abrasion resistance, moisture resistance, cold resistance, wet & heat cycle, hardy impact, light aging resistance, high temperature aging resistance, materials tensile.
华南理工大学锦丰科技集团
工程技术中心2012年 12月
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R&D
to P
rodu
ct D
evel
opm
ent
R & D Center
Design Section
Part design
Part analysis
Project Section
Part development
Tooling development
Engineering development
Laboratory
Inspection & test
Structure
All the economic activities revolve around R & D center as PDCA cycle.
DevelopmentProduction
Inspection
Delivery
R & D Center
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R&D
Inno
vatio
nsR&D of Microcellular Injection Technology Applied in Automotive Trim Products
Innovation: The application of Microcellular Injection Technology satisfied the requirements of auto parts impact resistance, high rigidity and free distortion. In addition, it adapts to the trend of Lightlizing automobile and broadened design approaches of new components & parts for new model.
It has become BSM proprietary technology and broadened design approaches for new products with more innovation.
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R&D
Rev
erse
Eng
inee
ring
R&D of High Performance of Light Transmission Injection Technology Applied in Automotive Trim Products
Innovation:R&D of High Performance of Light Transmission Injection Technology satisfied the requirement of high optical conductivity on automotive components & parts. In addition, it adapts to trend of individuation in automobile industry and broadened design approaches of new components & parts for new model.
The comparison of part researched & made by BSM and the one made in
Japan. (BSM made is better)
It has become BSM proprietary technology and broadened design approaches for new products with more innovation.
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R&D
Lab
orat
ory
Equi
pmen
t lis
t
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Engi
neer
ing
and
Anal
ysis
Technical Dept. has 8 senior engineers, who are specialized to do DFM and Moldflow.
Technical Dept.
Design Dept. has 40 design engineers, they use Pro Engineer, UG, SolidWork, AutoCAD and Master cam UG to design and program.
Design Dept.
Tooling Dept. has about 200 professional mold makers. We can produce 700~800 sets of molds per year, from 150mmX150mm to 2.5mX3.5M, up to 40T.
Tooling Dept.
We do trial-production and keep the mould running well in the machine for around 6 hours.
Mold Trial Team
Mold Checking Team has 10 Mold checking engineers. They check the manufacturing process and inspect the molds.
Mold Checking
Team
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Engi
neer
ing
and
Anal
ysis
DFM Report Tooling Manufacturing Process Trail Preproduction Report Mold Checklist
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Tool
Mak
ing
Capa
city
CNC - 19 Machines• Maximum machining capability 3.2 x 1.9m• Mori Seiki CNC machine, 1500 x 600m, tolerance ±0.003mm• Mikron CNC machine, 710 x 400mm, tolerance ±0.005mm• Fanuc CNC machine, 500 x 400 x 200mm, tolerance ±0.005mm
EDM – 15 Machines• Sodick mirror EDM machine, tolerance ±0.002mm• Other EDM machines
Wire-cut – 9 Machines• Makino Wire-cut machine , tolerance ±0.005mm• Charmilles Wire-cut machine , tolerance ±0.005mm• Sodick Wire-cut machine, tolerance ±0.002mm• Tolerance ±0.002mm
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Tool
Mak
ing
Supp
liers
Steel
Hot runner
Texture
Mold base
Resin
Hydro-cylinder
Standard parts
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ROU
SH/F
ORD
/CH
RYSL
ER
Ded
icat
ed P
roje
ct M
anag
emen
t
Current Programs include;BSM >> Roush >> (Interior trim) FordBSM >> Roush >> ChryslerBSM >> Roush >> (exterior) FordBSM >> Roush >> HondaBSM >> Roush >> WilberBSM >> Roush >> Summit Polymers
3 years of successful Partnership $2.6mm in sales
Dedicated Roush Project Management team
90 tools in 2013, commitment for 120 tools in 2014
2013 Euromold Partner to show strong China partner
Full time dedicated Roush Engineer on staff with dedicated office space in Corporate facility and factory
Daily transportation for engineers to & from the factory
China cell phone and IT support
BSM Engineering support in America for quick design approval and tooling trials.
Global Projects, Duplicate tooling design for China, America and Europe
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SKO
DA
D
edic
ated
Pro
ject
Man
agem
ent
Wheel Cover
Middle Console
Middle Console Assembly
Middle Console Outer part
Middle Console Inner partB Pillar
Bar
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Del
phi/
BMW
Ded
icat
ed P
roje
ct M
anag
emen
t
CAC tank CAC Tank Inlet & Outlet Central wheel
Central panel
Lateral L/R defrost cover
Instrument panelSpeaker
Glove box
Radiator Outlet
Radiator Inlet
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TOYO
TA
Ded
icat
ed P
roje
ct M
anag
emen
t
Holder, Hood Stay
Rear Door Box Cover
Panel Sub Assy Instr Cluster
Finisher
Garnish Sub Assy Instr Cluster Finisher Lower
Centre
Quarter Panel Mudguard
Control Pillar Lower
Front Side Panel
Reclining Adjuster Release Handle
Door Console
Front Sear Hinge Lower
Cover Front FloorCup HolderFront Seat Cushion
Inner Shield
Grip Assy
Control Armrest Hinge
Rear Door Trim Lower
Front Seat Cushion Shield Base Seat Track Bracket
Inner Cover
Front Fender Mudguard
Instrument Panel Under Cover LH
Console Box Insert
Instrument Panel Under Cover RHFront Door Armrest
Insert
Grill
Front Seat Cushion Edge Protector
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NIF
CO/H
onda
/Nis
san
D
edic
ated
Pro
ject
Man
agem
ent
Base Fr Lic Plate
Spacer Rear Bumper SideCover Filler Pipe
Cor Up Beam R&L Fr Bumper
Bracket Fog
ECU Cover
Upper Duct L&R Front Bumper
Cover & Holder
Garn &. Grille
Front Bumper Side
Upper Duct Front Bumper
Cover Intake
Cover & Cap T Gate Bracket
Garn Rear
Garn Control
Garn Rear Corner
Garn Ctr Corner
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Capa
city
Pla
nnin
g>>Capacity Planning to insure good workflow
>>Capacity Panning PO vs Capacity to identify potential bottlenecks
>>Detailed workflow planning with alert systems
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Inje
ction
Mol
ding
Cap
abili
ties
35 injection machines with robot from 50T to 2000T • Toshiba high speed injection machines from 100T to 350T• Vertical injection molding machines• Haitian injection machines
Trial run – In-house tooling trials
High volume production• ABS, PC, PC + ABS, POM, PMMA, PA, PPT, PE, PVC and other common materials and engineering plastics
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Inje
ction
Mol
ding
and
logi
stics
3 years partnership $2mm Tooling, $1mm Molding
Dedicated Pacific Insight Project Management team
110 tools in 2013, commitment for 140 tools in 2014
Rapid prototyping tooling and production tooling
Molding We produce all molded parts and ship to
Mexico for final assembly
Transfer tooling from other Asian and Canadian molders
We manage all logistics to Mexico and have a warehouse inside of PI to manage materials
We have a dedicated BSM employee to manage quality and the warehouse in Mexico
BSM Engineering support in America, full time BSM engineer on staff at Pacific Insight in Detroit, USA.
Current Programs include;BSM >> Pacific Insight >> FordBSM >> Pacific Insight >> GMBSM >> Pacific Insight >> Caterpillar
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Seco
ndar
y O
pera
tions
&
Asse
mbl
yUltrasonic welding Laser engravingElectro platingScreen printing Spray painting
RoboticFully automatedUV cureAnti-staticPU paint
Advanced inspection
4 automated production lines with robots built with reference to Toyota Thailand standards. 2 of 4 are under constant temperature and humidity control
Class 100,000 clean room
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Qua
lity
Syst
ems
Certifications ISO9001:2008 since 2006 ISO14001:2004 since 2008 TS16949:2009 since 2010
BSM have the systems in place ensure traceability down to every process on a single part, component and material; from design to delivery.
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Qua
lity
Syst
ems
for
Auto
moti
veDrawing
Failure effect analysis
Drawing
Failure mode analysis
Process flow
Product characteristics list
Process flow analysis
Product characteristics analysis
Customer complaint, defects card—
experiences accumulation
Severity evaluation reference table
Failure detection evaluation form
Failure incidence evaluation form
Effect severity evaluation
RPN evaluation
Failure detection evaluation
Failure incidence evaluation
Failure mechanism analysis
RPN acceptance evaluation
Process improvment
Continual improvement
Note: Process route - - - -→ Information route →
OK?
Y
N
A new mold
Contract review:Variation analysis
Confirmation of APQP requirement
Project team establishment
DFMEA
Functional requirements considerations/ Preliminary special product process characteristics identification
Focus on special product process characteristics according to function
Mold design Risk based design
Design verification plan Risk based verification
Manufacturing process flow chart
New equipments/ facilities/gages/supplies
Risk based verification
PFMEA Risk based design
Manufacturing process verification plan
MSA plan Risk based analysis
Pre launch control plan
Pre launch
MSA/ process capacity study/ product verification/
process evaluation
Manufacturing control plan
Work instruction
PPAP Production validation PPAP Submission
Confirmation of special product process characteristics
Feedback
Acceptance criteria of manufacturing process
P-FEMA APQP
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3Future Planning>New Factory>Larger tooling build capacity>More Automation>Advanced Capacity Planning
Future Developments
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New
Fac
tory
The Bluestar Industrial City is being designed as a self sufficient industrial zone dedicated to the production of molds and injection molding with the intent of becoming the worlds premier location for tooling design, injection molding and cutting edge technology. Additional facilities will be build for subcontractors for the supply of components and services to support the tooling and molding industry.
Bluestar Industrial City Layout Large-scale Mould Factory (covered parts)Precision Mould FactoryOptical Mould FactoryMedium-Sized Mould FactoryAuto Parts Manufacturing Factory oneAuto Parts Manufacturing Factory twoOffice Equipment Parts Manufacturing FactoryBusiness CenterR&D and Training CenterTechnical School
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New
Equ
ipm
ent a
nd
Auto
mati
onAutomated Assembly to reduce cost and increase efficiency and quality.
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Larg
er to
olin
g up
to 5
0TO
N
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Criti
cal a
spec
t of T
echn
ical
Ce
nter
Technical Center
Product Construction and
Analysis
Mold Construction Plastic and Steel Analysis
Injection Molding Technical Analysis
Import Dimensional Control
UG Secondary Development• Industry Standards• Customer Standards• BSM Standards
Engineering
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Flow
cha
rt w
ith N
ew F
acto
ryTooling
onlyCustomer
Tooling only
Customer
Tooling & molding
Customer
Tooling & molding
Customer
Sales/Project Managment
Technical CenterR&D Center
Engineering 3D/2D
Engineering Machining Processes Measurment and Controls (PMC)
Machining/Assembly
BSM Factory JF BSM Factory New
tryout and Approval
Machining/Assembly
tryout and Approval
Inspect and ship mold to customer
Transfer to BSM Mold production
Inspect and ship mold to customer
Transfer to BSM Mold production
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Oth
er C
usto
mer
s of
Blu
esta
r
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1. ?
2. ?
3. ?
4. ?
Collaboration