Manufacturing
Lean Manufacturing Principles that lead to more economical solutions for our customers. Sunhillo is an established manufacturer capable of design, development, evaluation, repair, and testing of advanced electronic equipment, ensuring that applicable CMMI, ISO/IEC 12207, J-STD-061-1995, IEEE, RTCA/DO-178B, UL, CE, MIL-STD, FAA-G-2100, FCC, RoHS and commercial manufacturing standards are adhered to.
Our processes operate to lean manufacturing principles, delivering maximum responsiveness and flexibility on behalf of our customers, also enabling us to compete successfully in global markets.
Our 32,000 sf facility delivers a wide array of production capability and opportunity for expansion. We deliver world-class manufacturing through our established processes via the operations management systems (Factory Management System (FMS), Material Requirements Planning/Enterprise Resource Planning (MRP/ERP)). Using our proven processes, we track and report the status of assets associated with assigned programs from induction through shipment.
We proactively and continually determine the materials, manpower, special tools, and test support necessary to accomplish assigned tasks. Sunhillo also participates in the development of cost proposals involving depot activity.
Sunhillo supplements in-house processes with an extensive supply chain of complementary suppliers organized in process clusters. The company therefore has access to an impressive range of materials and component suppliers. Kanban disciplines are internally followed and with qualified external suppliers-- this discipline minimizes stock and replenishment lead times.
Our quality program and processes support continuous improvement initiatives. Teams naturally interface cross functionally with representatives from other operations functions, including logistics, engineering, program management, supply chain management, and contracts.
Lean implementation is therefore focused on getting the right things, to the right place, at the right time, in the right quantity to achieve perfect work flow while minimizing waste and being flexible and able to change. These concepts of flexibility and change are principally required to allow production leveling and production flow. The flexibility and ability to change are within bounds and not open-ended, and therefore not expensive. More importantly, all of these concepts are reinforced, understood, appreciated, and embraced by Sunhillo employees who build the products and therefore own the processes that deliver the value. Our culture of "Lean" is just as important as, and possibly more important than, the actual tools or methodologies of production we use.
We also specialize in technical refresh and emerging technology prototypes and complex projects in low-to-medium volumes. We have the ability to transition to higher volume through offshore production. Sunhillo-
- Supplies systems, sub-systems and components
- Is supported by an extensive and competent supply chain
- Handles all aspects of sourcing, manufacturing and distribution
- Has the highest standards and progressive approach to quality management
- Strives to be ‘Right the first time, every time’
- Globally competes
Production planning is critical. Sunhillo plans, prepares, issues and controls production schedules and coordinates with material requirements to ensure a controlled flow of approved materials timed to meet production requirements. Utilizing our established MRP/ERP system, we coordinate material movement between warehouse/storeroom and production areas. The production planners continually advise management of the status of work in progress, material availability, and potential production problems to ensure that personnel, equipment, materials and services are provided as needed. A Master Scheduler drives equipment and personnel requirements, confirms material supply and demands, prepares work orders or purchase requests for the production or purchase of components or parts based on a master production schedule, shop load and/or inventory requirements.
Production leadership coordinates interdepartmental activity with quality assurance, manufacturing, purchasing, engineering, inventory control, traffic, contracts administration, etc.; schedules and expedites the movement of parts by means of move orders, stock transfers and requests for shipping orders. Read More
Rack Integration
Experienced Team and Proven Processes assure the job is done right.
Sunhillo brings comprehensive rack fabrication and systems integration experience, established and proven fabrication processes, an established and streamlined ERP/MRP systems, tools and techniques plus innovations that will insure success on any rack assembly and fabrication project or program.
Dynamic Process FlowFlexibility in Sunhillo systems accommodates dynamic designing by the customer, efficiently processing even “on-the-fly” changes driven by COTS lifecycle and supply-chain issues, while maintaining control of the process and without impacting quality of the final product. Any complications posed by defective/non-conforming customer-furnished-equipment are overcome by working with our customer to develop alternatives and workarounds. We provide complete "rack and stack" capabilities.
Given the short timeframe between design and deployment on many projects, Sunhillo works hand-in-hand with our customers to handle design and drawing shortcomings that will certainly minimize any impact to schedules and production quality, eliminating most risk elements. Sunhillo also implements asset tracking of top-level assemblies, sub-assemblies and component parts via our MRP/ERP system. This enables part traceability from component to rack and site level. 
Core capabilities and constant Communications Sunhillo rack fabrication personnel have extensive experience in air traffic control programs, critical defense systems, networking technologies as well as training in electrical/electronic technology. In addition, they have experience in manufacturing engineering and production planning.
Early and continuous close communication with customers is essential to Rack Production System success. This includes: feedback on initial program requirements, flexibility in resolving design issues, coordinated review of design changes, and development of peer-to-peer channels of communications with relevant parties.
Interleaved ISO 9001:2000 processes
1. Quality Management System – IAW Sunhillo ISO9001 processes, Sunhillo Quality Assurance (QA) personnel are an integral part of rack production from overseeing incoming inspection, to reviewing updates to procedures and work instructions, to auditing existing procedures. QA also provides incoming inspection and other training to Production personnel. QA also provides interface to a customer’s quality organization, tracks supplier performance (including CFE/GFE source suppliers), and establishes and monitors quality performance metrics.
2. Program Management System – Sunhillo Program Management (PM) provides cost, schedule, and performance oversight of rack production. Based on customer requirements and schedule, SPM establishes an Integrated Master Schedule, which is used by Rack Production to establish a rack build schedule. Our program management also provides oversight of consigned equipment (CFE or GFE) processing and handling to ensure proper accounting and tracking of CFE. PM is also responsible for evaluating and monitoring cost and schedule performance on customer change orders. SPM also oversees rack configuration management, which includes cataloging, handling, and distributing customer-furnished-information (CFI) such as rack drawings, parts lists, test procedures, and test software.
3. Sunhillo Engineering – Engineering works closely with Production staff to troubleshoot production issues and develop or refine test procedures. Sunhillo Production personnel are also give the opportunity to assist Sunhillo Engineering on tasks that permit learning of new skills and capabilities. This has the effect of enhancing their value to Sunhillo Production, or even allow them to move into other Sunhillo tasks. Sunhillo Engineering also possesses CAD expertise and capabilities used to support Sunhillo Production.
4. Accounting System – Integration between Sunhillo Production and Finance enables the capture of production labor and material costs based on work packages developed by Sunhillo Accounting with PM and Production input. This enables accurate cost reporting, tracking, and monitoring.
Life Cycle Sustainment and Support
"Cradle-to-Grave" mentality and processes from the start. Our services provide identification of key performance and related support parameters for inclusion in a Capabilities Development Document (CDD) and their basis as design requirements for subsequent phases that affect availability, reliability, maintainability, interoperability, manpower, testing, certification and the ultimate deployment footprint – the overall capability of the system to perform and endure in the required mission operational environment.
Our suite of services includes:
· Market analysis for system and product support capabilities (public and private) to define extent and scope of opportunities for achieving support objectives through design and viable product support strategies. This analysis encompasses:
o Elements of support currently provided (for legacy systems to be replaced).
o Current measures used to evaluate support effectiveness.
o Current efficacy of required support.
o All existing support data across the logistics support elements.
o Assessment of existing technologies and associated support that impact the new system under development.
· Initial identification of support related risk and risk mitigation planning, incorporating the:.
o Design and technology (e.g. low-observables, non-COTS, etc).
o Future projections of domestic and foreign facilitation and logistics infrastructure.
o Cost drivers.
· And where applicable, the requirements for providing sustainment during advanced stages in the procurement including during technology oriented demonstrations.
Fielding Plan - System Operational Effectiveness
Our fielding plan details the coordination and execution involved in the deployment of a system or equipment, and addresses interoperability opportunities and constraints. The plan includes sufficient information for a common understanding between the program sponsor and the ultimate end-sure for equipment quantities, implementation schedules, skill qualifications and training, and any additional manpower, facilities, or support requirements.
Upon fielding, an assessment framework is critical to make explicit the cause and effect relationship between design decisions and their impact on system operations, maintenance, and support that is essential to influence new and upgrade program development efforts from the longer-term life-cycle perspective. This becomes even more urgent with increasingly greater utilization of commercial-off-the-shelf (COTS) elements within information and knowledge intensive systems in the commercial, aviation, defense and aerospace domains. These architectures are often characterized by an evolving physical baseline (technology refreshment) driven by obsolescence and end-of-life risk considerations. A System Operational Effectiveness (SOE) analysis serves as a generic framework for a holistic system assessment by balancing factors pertaining to system performance, availability, process efficiency, and cost. Then, given the significance of system training costs, the results of a complete survey of the system training metrics and methods. This survey and effectiveness analysis is conducted to help understand training metrics currently utilized with a particular focus on the effectiveness of information and knowledge sharing. The subsequent objective is also to delineate architectural and technical attributes that can be used to assess system architecture and technology goodness with respect to availability, reliability, maintainability and cost. Read More