Composite Production Support Services
"Develop or add composite manufacturing capacity, improve production efficiency, or eliminate costly product returns."
CSS' Composite Production Support Services benefit the implementation of new fiber reinforced polymer (FRP) composite production lines through large and small composite manufacturing optimization programs.
Composite processes such as hand layup, roll wrapping, compression molding, Bladder Inflation Molding (BIM), resin infusion (e.g., VARTM, RTM), and combinations thereof are supported manufacturing methods.
CSS Composite Production Support program deliverables may include:
New Production Lines
- Production Tooling Design
- Production Work Cell Layout
- Standard Operating Procedures
- Manpower Estimates
- Product Specification(s)
- Test Methods & Quality Specifications
- Process & Job Travelers
Existing Production Lines
- Tooling Design Optimization
- Equipment Utilization Improvements
- Work Flow Improvements
- Idle Time Reduction
- Process Automation
- Material Scrap Reduction
- Rejection Rates Reduction
- Warranty Problem Resolution
CSS will often generate critical composite product, process, and production documentation including detailed Bill of Materials, Product Specifications, Process Specifications, Test Methods, and Standard Operating Procedures when transitioning from a successful Composite Product Development effort to support of a new composite production line start-up.
Our experience manufacturing composite products both domestically and 8000 miles away in China composite factories (Overseas Composite Production) also makes CSS uniquely qualified to evaluate the challenges and benefits of bringing composite production back to the States.
A Client tasked CSS to conduct an in-house manufacturing feasibility study to determine if reshoring their high volume composite production lines was viable.   CSS' evaluation considered tooling and equipment needs, manual and automated manufacturing operations, scrap rates and rework, work cell design, production flow, floor space requirements, worker health and safety, and specific Client needs in the study.
In addition to estimated capital, staffing, and training requirements, a detailed manufacturing unit cost analysis spanning a multi-year production transition period was performed to determine if reshoring was worthwhile and if reshoring would pay dividends.
CSS' program deliverable ultimately served as a blueprint for reshoring the Client's production lines when the timing is right.