Success in business starts with an organization’s people, the engine for great service delivery. The folks at Sypris believe in helping our customers build trust – trust that your customers can experience through your efforts and product delivery. We have a long standing approach of a Lean/Six Sigma, continuous improvement culture that senior leadership cultivates through internal investments. Long term relationships we create with customers are the outcomes of our Service Experience.
“Sypris has a broad set of operation capabilities to support your contract manufacturing needs – but is important for you to understand how we do it,” states Jim Long, Sypris Vice President of Operations. “Our approach is to be an extension of your team and is centered on the fact our customers trust Sypris to deliver!” Our proven design talent, manufacturing and testing processes fully supported by industry wide lessons learned and test engineering, along with a solid program management vision and strategy allow for successful execution to the critical program requirements. Having a trusted partnership, with proven credentials drives that program risk to near zero.
Sypris Electronics operates in an Integrated Product Team (IPT) structure to deliver our customers direct, transparent and timely value. Risk and opportunity management is integral to the IPT processes; it is a continuous and iterative process that accounts for risk mitigation planning, identifying, handling, and monitoring and reporting of risks and opportunities throughout the program life cycle. The primary objective of risk management is early identification, continuous tracking, and systematic reduction of elements that could influence the program’s ability to meet its technical, cost or schedule objectives.
Continuous Improvement Culture
The Sypris culture is built on a foundation of the fundamental principles of respect for people, integrity in all we do, the pursuit of perfection, and the creation of value for all stakeholders. Within this framework, we have adopted and deployed systems, methods and tools such as Lean, Six Sigma, Hoshin Policy Deployment, and Program Management Institute (PMI) Project Management Professional (PMP) training and certification to accelerate our business performance and cultural evolution.
Customers can truly extract substantial and tangible value from our Continuous Improvement efforts. We have successfully run co-innovation workshops and co-Kaizen events with some of our customer partners, resulting in reduced customer build-to-print costs. In one instance, we assisted a customer in redesigning their product on the basis of our joint Kaizen event to improve their Rolled Throughput Yield (RTY) and significantly reduce cost. Our design ability in electronics combined with our process and manufacturing knowledge, uniquely enables us to achieve measureable results.
What Makes our Partnerships Work?
Culture is foundational to success, but the combination of our people’s talents and processes they work through foster our thriving customer partnerships. Throughout the ongoing partner exchanges, the skills and expertise of the Sypris IPT create an environment of transparent communication and collaboration to assist in program execution. Shared responsibility to grow our relationships with our customers is channeled through Program Managers and Business Development Managers. Their core leadership on the IPT is central to all phases of the programs beginning at the onset of a project when initial knowledge transfer is paramount to a down the road successful delivery. The IPT Discovery Team it deployed to a customer’s site to conduct a complete survey to on-board the new program.
The IPT is the focal point for total project visibility and senior leadership involvement. This has consistently led to strong performance in meeting our customers’ needs. Some advantages are:
- Excellent cross-functional communication to ensure problems are resolved quickly and effectively
- Consistent application of best practice tools to drive process flow and stability that impacts performance most important to the customer
- Team learning through a cross-functional view of impediments to performance
The Sypris IPT is more than the customer-facing staff alone. Skilled operators and production managers fulfill customer requirements under the direction of a Program Manager. With weekly Sypris-Customer meetings, projects are tracked and issues are addressed. Other IPT members such as Sypris Process Engineers actively address the job at hand whether it’s developing a new manufacturing process such as heat sink bonding, designing safe handling fixtures, or updating Manufacturing Work Instructions to accommodate Engineering Change Orders (ECO) directed by the customer. Having a competent engineering staff at the Sypris facilities, allows for smooth flow of production and helps to eliminate sub-contractor “babysitting”.
Another comforting element of the Sypris partnership is our Trusted Source Supply Chain Management (SCM) capabilities. Sypris SCM complements our partnerships with worry-free materials and component procurement supporting scenarios of Customer Furnished Materials (CFM) to full Turnkey Material Acquisition and in some cases a hybrid case. To prevent the risk of counterfeit material, our proven network of Original Component Manufacturers (OCM) and certified, top franchised distributors are the conduit of our trusted SCM providing electrical, electronic, and electromechanical (EEE) parts.
Addressing Risk Mitigation
In the manufacturing world of high reliability, risk is always on a customer’s mind. Do we outsource to save costs? Will my contract manufacturer build to the quality standards we have in-house? Our project is mission critical – do we risk our products to be delivered on-time by someone else? This is their worry list. Understanding how your manufacturing partner mitigates risk is essential.
From the onset of a new customer program, Sypris Electronics utilizes a Process Failure Modes and Effects Analysis (PFMEA) as an integral part of product and process design activity. This critical operational tool is used to identify, assess, and manage risks associated with the design features and attributes of this product. As part of our New Product Introduction (NPI) process, Sypris will develop a PFMEA for your product based on the product and process requirements provided to the Discovery Team, as well as its experience in the manufacturing and testing of high reliability application electronic products. Some of the benefits to using a PFMEA process are: error proofing, improving potential process capabilities, and instituting a control plan methodology.
A further example of mitigating risk and implementing standard processes, Sypris Electronics utilizes the Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) scientific method as the standard approach for solving problems. Six Sigma training has been deployed to individual contributors, mid-level managers, and executives throughout the organization. Some of the typical tools used are: Process Maps, Thought Process Maps, Control Charts, Pareto charts, Measurement Systems Analysis, and Design of Experiments.
“Lean Enterprise” is a fundamental component of Sypris Electronics’ Continuous Improvement culture. Lean activities, using the Plan, Do, Check, Act (PDCA) approach, are deployed as cross-functional activities throughout the organization to eliminate waste and improve throughput. Lean activities consist of Baseline Events, Kaizen Events, and “Just Do It” activities. Lean training has been deployed using internal training prior to events as well as by external academic institutions. Every employee participates in Lean activities helping to drive these principles as part of the Sypris Electronics culture. The Lean Enterprise Culture is augmented by numerous certified Lean Experts on staff, and is fully integrated with all the Six Sigma efforts. The tools and practices employed include 100% Lean Launch on all products, complete Lean Cell Design and Scale-Up, PFMEA Pre-Build Reviews, DFX Collaboration with the customer, and Co-Kaizens with the customer.
To prevent future risk and to help reduce overall production costs, we approach product designs with DFx prinicples. Our engineering design service function encompasses design for manufacture (DFM), design for assembly (DFA), design for test (DFT), and design failure mode and effects analysis (DFMEA). Formal documentation control, extensive technical design expertise, as well as mechanical, software and environmental test engineering services are available as required to support the customer’s product
Quality Management System
Sypris Electronics operates using a Quality Management System that is compliant to and certified to AS9100 and ISO9001. Producing and delivering the highest quality products and services is our primary focus of being a “Trusted Source” for our customers requiring high-reliability solutions.
Every step throughout the Sypris business process addresses and manages risk. A Quality Program Plan is developed for every program or product family. Sypris utilizes Failure Modes and Effects Analysis (FMEA) early in the on-boarding process to identify higher risk areas. We then implement appropriate controls plans to ensure high levels of quality and reduce risk for all stakeholders.
Sypris has a robust process for sourcing raw material and components. Processes are in place and executed to qualify vendors, perform first article inspections in accordance with AS9102, continually monitor raw material quality through receiving inspections, and close the loop on supplier performance using and analyzing supplier scorecards.
Once raw material reaches the production area, products are assembled by trained and certified operators. Operators are trained and certified to IPC-610 Class 3, J-STD-001 Class 3, J-STD-001 ES, NASA-STD-8739.1, .2, .3, and .4. Sypris maintains capability on staff to deliver training and certifications to operators thereby removing risk of having to certify operators with outside training providers. All products assembly is directed using electronically delivered Manufacturing Work Instructions and Standard Operating Details.
Sypris facilities comply with S20.20 Electrostatic Discharge (ESD) requirements, and measurement equipment calibration is provided by an in-house accredited provider.
All Sypris business, manufacturing, and test process are supported by personnel with a strong culture based upon the principles of Lean and Six Sigma. A significant number of trained and certified as Six Sigma Green Belts and Black Belts are embedded throughout the organization to drive continuous improvement, proactive risk mitigation, and structured problem solving.
Experience Sypris Services
In the end, quality is a given, but it must go hand-in-hand with timely delivery. Sypris understands through years on of lessons learned and best practice implementation, that the job isn’t complete until it’s delivered to our customer to fulfill their customer requirements. We are ready to support the build of your successful program, in a trusted partnership, all with minimal risk!
Come experience Trust Beyond Manufacturing™.
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