Composite Production Support Services
"Develop in-house composite manufacturing capability, improve production efficiency, and 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 manufacturing operations such as hand layup, lamination, roll wrapping, compression molding, bladder molding of prepreg and infused preforms, resin infusion (e.g., VARTM, RTM), and combinations thereof are supported in Composite Production Support programs which draw from the following engineering services:
New Production Lines
- Define Manufacturing Operations
- Design Production Tooling
- Layout Production Work Cell(s)
- Create Standard Operating Procedures
- Provide Manpower Estimates
- Develop Product Specification(s)
- Create Test Methods & Quality Specifications
- Organize Process & Job Travelers
Existing Production Lines
- Optimize Tooling Design
- Improve Equipment Utilization
- Improve Work Flow
- Reduce Idle Time
- Automate Key Operations
- Reduce Material Scrap
- Lower Rejection Rates
- Resolve Warranty Problems
In many cases CSS generates critical composite product, process, and production documentation including detailed Bill of Materials, Product Specifications, Process Specifications, Test Methods, and Standard Operating Procedures following successful Composite Product Development efforts.
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.
FRP composite product design or production related questions?   Please contact us to discuss your composite program needs.