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For this workshop, First Part Correct is defined as the ability to
transition from design concept to a finished product with absolute
certainty of a correctly produced part or product. Emphasis is on the ability to produce the first product
correctly and to transition from one to many without interruption.
The elements of the functional model include:
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Integrated Product and Process Development
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Includes all activities associated with
transitioning from concept and customer requirements to a best
product design that is producible by efficient and optimized
processes utilizing resources that are capable of performing the
necessary functions within a stable envelope.
Integrated product, process, and resources in a concurrent
environment.
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Manufacturing Execution |
Addresses the provision and execution of
manufacturing processes, that are characterized and in-control, to
accurately produce product according to the process instructions. Also included is the ability to integrate and exploit
technological advances to enhance the ability to deliver first part
and every part correct.
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Supporting an infrastructure for First Part
Correct
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Embraces the broader environment for producing
product and includes business operations and functions, the training
and sustainment of a qualified and motivated workforce, issues
associated with the supply chain and the extended enterprise, and
requirements for an integrated approach to product delivery.
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Integrated Product and Process Development
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Product and process design
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Includes all functions required to transition
from the definition of wants and needs to requirements and design
criteria and then to product and process design.
The ability of the processes and resources to deliver
according to potential design options is a part of the holistic
design process
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Product and process modeling and simulation
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Includes all activities required to assure that
product design options will deliver needed performance at acceptable
cost and that process design options will all operation within
acceptable limits of process parameters – utilizing available
resources. The
integration of product and process modeling for “virtual
prototyping” within a test environment that enables the evaluation
of design options is also included.
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Manufacturing Execution
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Traditional Processes and Controls
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Includes the execution and control of
traditional manufacturing processes.
Incorporates the concepts of characterization of equipment
and processes for the establishment of deterministic processes
whereby the product is always as intended – without the need for
off machine inspection for certification.
Intelligent control is included as a key success ingredient.
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Non-traditional processes and emerging
technologies
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Addresses issues associated with alternative
processes and their ability to deliver first part correct.
Also includes emerging technologies and technological
directions that may influence how product is manufactured.
Includes issues associated with the implementation of
emerging technology and alternative processes.
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Supporting infrastructure
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Managing business operations
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Includes the functions necessary to assure that
businesses can support the operational needs for first part correct.
Addresses connectivity issues, configuration management, data
exchange, network requirements, etc.
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Sustaining an FPC culture
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Includes all workforce and workplace issues
including the establishment of skills requirements, the assurance of
qualification, the motivation to “do it right”, and the
establishment and maintenance of a team environment.
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Supply chain management and integration
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Responds to the reality that making a product
across a distributed supply chain presents challenges not present in
a laboratory. Addresses
issues of on-line collaboration, common languages and standard
operating procedures and shared cultures.
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