strataplex, inc. innovations delivered! strataplex, inc. confidential the art and science of global...
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Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
The art and science of global product development and operations –
A silicon valley perspective
K.R. SubramanianPresident, Strataplex, Inc.
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Do you think this happens only in cartoon….?
Communication, cooperation, team work, alignment…….
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Then, think again………
Communication, cooperation, team work, alignment…… continued…..
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Welcome to the real world of Global Operations….
Case study 1:
Company: Leading fiber optic components supplier in the world
Objective:
What: Transfer the components manufacturing operations to a CM in Thailand.
Why: To enable the company grow into sub-systems and systems business
Simple enough objective.. However …
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Customer OEM/CM
Location San Jose, CA, USA Bangkok, ThailandEthnic Mostly Chinese All Thai, one Caucasian CEOTechnology Fiber optics ElectronicsProduct expertise High degree of customization Cookie cutter, high volumeCompany discipline Loosely bound documentation Rigor of ISO 9001, 14001Experience No CM outsourcing ever Never worked in opticsPopulation Mostly engineers Mostly assembly skilledMood Don’t want to outsource Don’t have a clue
Have not done this before…. thus we did not know where to begin
Simple enough objective.. However the disparity in environments was huge…
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
If you do not know where to begin…Let us mind map
After the mind map, dinner, beer and some lattes to fight 15 hour time difference, we had more confusion…… But we are getting somewhere; at least we knew what needed to be done… (so we thought!)
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Next few weeks we worked on
More important stuff…. Like
• Management alignment and assurance• Fostering team work across teams• Developing trust, overcoming fears of letting go• Staying objective versus emotional• Process focused rather than knee-jerk reactions• Understanding, respecting each other’s strengths and weaknesses• More lunches, beers, dinners, cigarettes and lattes
And, on the less important stuff….. like
• Technology alignment• Optics and electronics integration• Assembly tools, processes• Product specifications, testing• Engineering and manufacturing documentation• Supply chain and logistics• Technical and process training• Qualification and reliability
Making progress
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Techniques and processes used….
• Factory visits to understand each other’s capability• Getting to know the “team mates” on the other side• Solving issues as one entity• Ensuring job security for the USA folks• Developing business process flows• Daily, weekly communications• Documenting, following through action items• Picture is worth a thousand words• Utilizing best practices from both sides
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
What did we accomplish
• Upward momentum – started outsourcing other components
• ISO discipline ( though not certified)
• Out of the box thinking in design for manufacturability
• Operations thinking from concept stage
• Customer became vertically integrated to systems business
• CM became number one in the fiber optic components industry
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
What it takes to read a bit of information
Hard disk drives, all hand assembled
ElectronicsElectricalServoMagnetismAerodynamicsMechanicalTribologyThermalWafer processingMaterial science
And…
A “bit” of luck
Case Study 2
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
Read write / Disk drive Product Life Cycle
Co-development, 2 yrs Qualification 6 months
Volume,From 1000 to millions,3 months
EOL
Transfer
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
• Supplier, R&D• Customer R&D
• Customer Manufacturing
• Supplier Manufacturing
Supplier, San Jose, CATeam of 40 people
engineers, logistical support, program management and customer service
Customer, San Jose, CA
Team of 20 – 30 people in R&D, manufacturing,
management and reliability
Supplier:100s of people in pilot transfer team, 5000 – 20000 operators and
manufacturing folks in assembly in two
locations, Philippines and Thailand
Customer:1000s of disk drive
assembly, engineering, procurement
Triangular coordination - Environment
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
• Supplier, R&D• Customer R&D
• Customer Manufacturing
• Supplier Manufacturing
Supplier, San Jose, CATeam of 40 people
engineers, logistical support, program management and customer service
Customer, San Jose, CA
Team of 20 – 30 people in R&D, manufacturing,
management and reliability
Supplier:100s of people in pilot transfer team, 5000 – 20000 operators and
manufacturing folks in assembly in two
locations, Philippines and Thailand
Customer:1000s of disk drive
assembly, engineering, procurement
• Program management• Preparation• Co development• Technology transfer• Logistics and supply chain• Specification trade offs• Communication• Testing and qualification• Management approval
Triangular coordination –What it took
Strataplex, Inc.Innovations Delivered!Strataplex, Inc. Confidential
While most of the Silicon Valley companies, large and small, are based on science and engineering, global operational development is still a fine art that is so critical to success.
Thank You!
The moral of my story is……