When launching new products, one should progress through the product development stages (i.e. from product concept to finalised product) quickly and efficiently.
The introduction and use of design tools and methods should also take place, flexibly and effectively. Products should be designed with a view to ease of manufacture and assembly.
In dealing with production, it is essential to go beyond the question ‘How do I make a product?’
Other questions to respond to include:
How do I ensure that the necessary parts and tools come together at the right times?
How do I deal with failures?
How should I schedule machine maintenance?
How should I set up the sophisticated logistical systems required?
Automation play a key role in these sub-fields and simulation can help you trial out methods before you spend the money on manufacture.
Production Engineering involves design, control, and continuous improvement of integrated systems of people, machinery and materials in the production of new products and services with the aim of producing goods and services of high quality in time in a cost-effective manner.
This requires combining skills and knowledge within industrial engineering, manufacturing engineering, product design, finance & planning. These are an essential part of any production engineering effort, since the operation of a company depends on co-ordination of all areas of the production process; human, computing, materials, electronics, mechanical, and financial.
Use is made of a wide range of knowledge and techniques. These include statistical data analysis, computer simulation, operations research techniques, mechanical and materials engineering and industrial engineering techniques. A key element of modern production engineering is the use of computer and information technology to solve the ever emerging problems encountered in the modern production process.
Manufacturing
Our quality and customer focus is evident in everything we design, manufacture, test and deliver. It’s this emphasis on quality and complete end-to-end manufacturing solutions that drives our business and provides our customers with significant competitive advantages in the global marketplace.
An experienced manufacturing resource is a key building block for your product. By relying on our technical know-how, manufacturing your product with high quality standards, yet cost effectively is no longer a challenge; we have the expertise, technology, experience and reputation to ensure cost savings and increase time-to-market.
ISO9001-2000 and UL accreditation brings the security of quality and reliable processes. All our products meet CE and are ROHS compliant. Fully automated processes bring an opportunity to decrease costs and improve product lead times with access to multiple manufacturing facilities, worldwide
Automated Manufacture
Accuracy in manufacturing is essential. Micro Engineered parts endure tolerances in microns our automated manufacturing services work closely with key suppliers who can either directly transfer 3D files from our software systems.
Our methods utilise constraints that can be implemented into the design of a product throughout the 3D modelling stages giving greater control during production.
We continuously analyse production using our 3D laser scanning services, which allows data recording, highlighting errors. We transfer this data directly to CNC machines used for tooling, and prototype production. Product accuracy is achieved with greater efficiency this way, but it is not necessarily the most economical method and does not really suit low end product development or projects where time and low cost are the fundamental priority. During these options or where suppliers have been contracted before Intelligent Developments involvement, we also provide file conversion in many forms including the industry standard, iges, step and STL formats.
Automation
DFA is used for the design of products, suitable for rapid, efficient and competitive manufacturing. Hence, a more general term than that of the degree to which the design of components is suitable for the manufacturing process.
Each part is analysed with integrity and designed to aid automation flow and human-machine interfacing to simulate the product and it’s components to speed up time response of production. For example, the simple process of the analysis of handling and methods of insertion can also be of benefit when considering the time efficiency of assembly. The production of an asymmetrical part can be sometimes less efficient than a symmetrical part as orientation guides result in quicker handling time.
The additional work in executing DFA, helps the design team to focus on the clear objectives and prevent manufacturing issues and prevent time consuming re-work. We can develop our solid modeller systems to simulate the part in its processing stage and identify issues before tool manufacture proceeds.
Up to 50% of the total production life cycle and quality can be saved, enabling faster production as the pace market demand fluctuates.
Low Volume Assembly
Most products do not carry the criteria to necessitate automation. Others, such as larger housing assemblies can consider a hybrid, part hand assembly/part automation. Either way, ID can again, help in facilitating the design for specific needs and help manage the transition of handling, during and post production.
Tooling
Provision of an ID tooling standards booklet is provided to all contractors. Machinery development such as 5 axis, High speed CNC machines have situated themselves at the forefront of tool and prototype evaluation. Design packages provide a vast range of 3D CAM and Milling Software, produced to transfer Design data to manufacturing techniques.
Our Frequently applied processes include;
• Electronics assembly including; SMT • Die attach and wire bonding • Through hole.
Welding:
• Ultrasonic welding, both 40Khz and 20Khz for assembly of fully sealed products.
• Laser welding, both 40Khz and 20Khz for assembly of fully sealed products.
• DFM – Product assembly, miniature products right through to large, multifunction devices.
• Electronics Assembly including; SMT • Die attach and wire bonding • Through hole.
• Multi-shot injection moulding
• Glass/Carbon additive moulding
• Insert moulding
• Over moulding
• Rotational moulding
• Pressure moulding
• Vacuum forming
• ASEPTIC moulding
• MIM
• Stamping
• Pressing
• Casting
• MMetal sheet fabrication
• Steel fabrication
• CNC
• Pigments
• Silicon seals
• Rubber membranes
• Gear Configuration & Design
• Ultrasonic Horn design
• Connector design
• Snap fit design
• Transfer Printing
• Hot foil
• Pad printing
• Product Fascia’s
• Water jet cutting
• laser marking
• Welding
• Ultrasonic Welding
• Laser welding
• Friction Welding
• Stud Welding
• Meturlegy
• Sintering
• Deposition
• Coating
