Seminar Presentation Design Excellence For Manufacturing Sustainability V1

NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]

Page 1

Design Excellence for

Manufacturing Sustainability

Kamarulzaman Darus PJNDirector of Manufacturing NAM

[email protected]+6012-277-2059

Graduated in B.Sc. Mechanical Engineering from Graduated in B.Sc. Mechanical Engineering from Leeds University, UK. Leeds University, UK. Had been in the Automotive Manufacturing Had been in the Automotive Manufacturing Business for more than 25 years.Business for more than 25 years.Had been responsible in key areas of Production Had been responsible in key areas of Production and Planning, Manufacturing Engineering, Plant and Planning, Manufacturing Engineering, Plant Engineering, Product Research and Development.Engineering, Product Research and Development.Currently, the Director of Manufacturing Currently, the Director of Manufacturing ––responsible in all aspects of Manufacturing for responsible in all aspects of Manufacturing for NazaNaza Automotive Manufacturing.Automotive Manufacturing.


Page 2

MALAYSIA’S INDUSTRIALIZATION MASTER PLAN

Industrial Master Plan (IMP)1986 - 1995

• Ensure rapid expansion of the economy through acceleration of manufacturing sector growth

• Promote efficient and optimum utilization of natural resources through value-added manufacturing activities

• Lay foundation for the development of indigenous technological capabilities

Three broad objectives:

Industrial Master Plan 2 (IMP2)

1996 - 2005Moving beyond manufacturing operations to include :

• Indigenous R&D and technology

• Design Capabilities• Integrated supporting

industries• International marketing• Development of own Brand• World class, world scale

“MANUFACTURING ++”“MANUFACTURING”

We are now in the midst of IMPWe are now in the midst of IMP--3, which is basically a continuation of IMP3, which is basically a continuation of IMP--2 but focusing more on 2 but focusing more on statestate--ofof--thethe--art technology and research such as art technology and research such as nanonano-- and bioand bio--technology etc.technology etc.


Page 3

INDUSTRY CAPABILITIES TRANSFORMATION

MANUFACTURING DESIGN & ENGINEERING

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

VPDMVPDM

CADDS (ComputerCADDS (Computer--Aided Design System) CAD (EUCLID, Aided Design System) CAD (EUCLID, CATIA ® ), CAE, CAMCATIA ® ), CAE, CAM

PROTOTYPING PROTOTYPING -- Rapid Prototyping (SLA, LOM) , Rapid Prototyping (SLA, LOM) , Prototyping CentrePrototyping Centre

CMSS (4CMSS (4--Poster, Kinematics Rig,Poster, Kinematics Rig,Crash Sled, Components Tests Laboratory)Crash Sled, Components Tests Laboratory)

Climatic Chamber, Engine Test Cells)Climatic Chamber, Engine Test Cells)

MACDMACD

VIRTUAL PRODUCT VIRTUAL PRODUCT DESIGN & MANUFACTURINGDESIGN & MANUFACTURING

MILEAGE ACCUMULATION MILEAGE ACCUMULATION CHASSIS DYNAMOMETERCHASSIS DYNAMOMETER

CAR ASSEMBLY OPERATIONSCAR ASSEMBLY OPERATIONS

Local Vendors DevelopmentLocal Vendors Development

STAMPING & DIES MAINTENANCESTAMPING & DIES MAINTENANCE

JIGS DESIGN & MANUFACTURINGJIGS DESIGN & MANUFACTURING

ENGINE ASSEMBLYENGINE ASSEMBLY

DIES DESIGN & MANUFACTURINGDIES DESIGN & MANUFACTURING

CASTING and MACHININGCASTING and MACHINING

SHTT (SemiSHTT (Semi--High Speed Test Track), Emission and High Speed Test Track), Emission and Noise Laboratory (SemiNoise Laboratory (Semi--Anechoic Chamber)Anechoic Chamber)

STYLING, MODELING & ERGONOMICSSTYLING, MODELING & ERGONOMICS

Note:Major Tests and Validations would still beConducted in Tests Centers such as atMillbrook, Idiada, Crashlab etc.

1986 2007


Page 4

INDUSTRY DIFFERENTIATORS

INTEGRATED BY THE NPI SYSTEM

DESIGNED FOR THE MARKET

INTEGRATED BY THE NPI SYSTEM

DESIGNED FOR THE MARKET

Product VarietyProduct VarietyProduct Variety

Lower Volume Wider Range

Lower Volume Lower Volume Wider RangeWider Range

Reduced Product Lifecycle

Reduced Reduced Product Product LifecycleLifecycle

AutomationAutomationAutomation

MarketingMarketingMarketing

“Real-Time” Logistics

““RealReal--Time” Time” LogisticsLogistics

Market &ConsumerMarket &Market &

ConsumerConsumer

•• Flexible Flexible Manufacturing Manufacturing System (FMS)System (FMS)

CAD / CAM / CIMCAD / CAM / CIM••EDI, JITEDI, JIT••Configurable BOMConfigurable BOM

••Platform EngineeringPlatform Engineering••Modular EngineeringModular Engineering

•• Product Life Cycle Product Life Cycle halvedhalved

•• SE/CE TeamsSE/CE Teams•• CAS/CAD/CAE; VRCAS/CAD/CAE; VR

••Short Lead Time from Short Lead Time from Ordering to DeliveryOrdering to Delivery

KEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAINKEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAIN


Page 5

VALUE CHAIN

PRODUCT

STYLING DESIGN

TOOLING:STAMPING DIES,

PLASTIC MOULDS DESIGN & DEVELOPMENTPLATFORM

ENGINEERING

POWERTRAIN DESIGN &

MANUFACTURING

LOGISTICS &DISTRIBUTION VENDORS

COMPONENT DEVELOPMENT

and SUPPLY&

EQUIPMENT SUPPLIERS

COMMONPLATFORM TESTING

&VALIDATIONS

STAMPING BODY WELDING AND ASSEMBLY

FINAL ASSEMBLY

PAINTING

MARKET(SALES &

MARKETING)

PRODUCTENGINEERING

INTEGRATED AND DIFFERENTIATED BY TECHNOLOGY (DESIGN & ENGINEERING)


Page 6

INDUSTRY LEVEL OF CAPABILITIES

SUSTAINABLE MANUFACTURER ….. ECONOMIES OF SCALE ~ MINIMUM 30K/MOSUSTAINABLE MANUFACTURER ….. ECONOMIES OF SCALE ~ MINIMUM 30K/MODEL/ YEARDEL/ YEAR

ORGANISAORGANISA--TIONTION

••KnowledgeableKnowledgeable••UpUp--toto--datedateInformationInformation

BRANDINGBRANDING••“Own” Car“Own” Car

••“Own” Brand“Own” Brand

GLOBAL GLOBAL MARKETMARKET

ConsolidatedConsolidated••Global & Global & RegionalRegionalNetworkNetwork

QUALITY QUALITY PRODUCTPRODUCT••Low CostLow Cost••DesirableDesirable

••UpUp--toto--DateDate

QUALITYQUALITYCOMPONENTCOMPONENT••Competitive Competitive

••Global SourceGlobal Source

PRODUCTIONPRODUCTIONSYSTEMSYSTEM

••“Flexible”“Flexible”••‘0’ Defect‘0’ Defect••‘0’ Stock‘0’ Stock

CONSUMERCONSUMERLoyalLoyal

••Strong BrandStrong Brand••DelightedDelighted

ADVANCED ADVANCED MANAGEMENTMANAGEMENT••EmpowermentEmpowerment

••TeamsTeams

TIMELY, TIMELY, ACCURATE,ACCURATE,

AND AND INTEGRATEDINTEGRATED

INFORMATIONINFORMATION

SOUND SOUND PROCESSPROCESS

and CONTROLand CONTROL••FinancialFinancial

••HRHR

BASICBASICFUNDAMENTALFUNDAMENTAL

GLOBAL GLOBAL MARKETINGMARKETING

COMPLETE COMPLETE SUITESUITE

OF DESIGN OF DESIGN TOOLSTOOLS

& FACILITIES& FACILITIES(INCLUDING VR)(INCLUDING VR)

VENDORVENDORPARTNERSHIPPARTNERSHIP(1st TIERING)(1st TIERING)

FLEXIBLEFLEXIBLEPRODUCTIONPRODUCTIONSCHEDULINGSCHEDULING

MAKE TOMAKE TOCUSTOMERS’CUSTOMERS’CONFIGUREDCONFIGURED

ORDERSORDERS

GLOBAL GLOBAL PRESENCEPRESENCE••Selected Selected MarketsMarkets

••Strong in Strong in ASEANASEAN

DEEP DESIGNDEEP DESIGNCOMPETENCECOMPETENCE

INTEGRATEDINTEGRATEDSUPPLY CHAINSUPPLY CHAIN

SOUND SOUND MATERIALMATERIALPROCESS PROCESS

FLOWFLOW••JIT, CCJIT, CC

••KANBANKANBAN

MAKEMAKETOTO

ORDERORDER

MULTI PLANTMULTI PLANTOPERATIONSOPERATIONS

••OwnOwn••ContractContract

••CKDCKD

CROSS CROSS FUNCTIONALFUNCTIONAL

DESIGN TEAMSDESIGN TEAMS

MATERIAL MATERIAL COST COST

MANAGEMENTMANAGEMENT

GOOD GOOD PRODUCTIONPRODUCTION

SYSTEMSYSTEM••Process designProcess design

ASSEMBLE ASSEMBLE TOTO

DISTRIBUTORS’DISTRIBUTORS’ORDERSORDERS

PARTNERPARTNERDESIGNDESIGN

DOMESTICDOMESTICDOMINANCEDOMINANCE

BASIC DESIGN BASIC DESIGN TOOLSTOOLS

AND FACILITIESAND FACILITIES

VENDORVENDORDEVELOPMENTDEVELOPMENT

SIMPLE SIMPLE PRODUCTIONPRODUCTION

SYSTEMSYSTEM

ASSEMBLEASSEMBLETOTO

STOCKSTOCK

FULL RANGEFULL RANGEMODELMODELDESIGNDESIGN

‘‘ININ--HOUSE’HOUSE’DESIGNDESIGN

BASIC BASIC MODIFICATIONMODIFICATION

DESIGNDESIGN


Page 7

IAF (INDUSTRIAL ADJUSMENT FUNDS)

CKDCKD

AssembleAssembleLocalizeLocalize

60%60%

High TechnologyHigh Knowledge Application

High Employment

PLATFORMPLATFORMMFGMFG

RnDRnD CENTRECENTRE&&

ENGINE MFGENGINE MFG

OWN OWN PRODUCT PRODUCT

DESIGNDESIGN

1:10 = 100,000

1:1 = 600

Value Chain

1:6 = 40,000

25 years

Regressive

IPIP

HighLabor

Progressive

R&D Centre, R&D Centre, Product Design, Product Design,

Powertrain & Powertrain & Tooling Tooling

Manufacturing .Manufacturing .

CAPABILITY DEVELOPMENT


Page 8

PRODUCT DEVELOPMENT ELEMENTS

DESIREDDELIVERABLES

Engineering Simulation & Analysis

Plant Set-Up

Project Management

Vehicle Design,Engineering&Development

Process Engineering

Machinery,Equipment& Facilities

SimultaneousEngineering

Design

Performance

Cost

Weight

QualityDelivery

TOTALLY INTEGRATED IMPLEMENTATION

EFFECTIVEINITIATIVES

MANAGEMENT

MARKETBOARD

PRODUCTS


Page 9

ADVANCED VIRTUAL ENGINEERING

3D CADModeling

VirtualReality

CrashSimulation

DurabilityAnalysis

MetalFormingAnalysis

VehicleDynamicsAnalysis

DigitalMock Up

ToleranceAnalysis

Design

StylePresentation

SafetyControl

Structural Performance

FormabilityPossibility

DynamicPerformanceAssembly

Possibility

QualityControl

REDUCING DEVELOPMENT TI

MING & COST


Page 10

CONCURRENT ENGINEERING

To shorten the development time and reduce the cost of late design changes through early involvement of all stakeholders

during development

Planning Styling Proto Pilot Prod.

No

of d

esig

n c

han

ge

S.O.P

The desired

The historic

More cost for design change and market warranty

CAEMule vehicleAlias styling

Verification modelFormability

DMU


Page 11

COST CONTROL & BENCHMARKING

PAST Present

DesignDesign

Parts develop.Purchasing

Parts develop.Purchasing

ManufacturingManufacturing

Cost totalingCost totaling

Estimatedsales priceEstimatedsales price

Target cost set up

Target cost set up

DTCDesign To target

Cost

Sales priceSales price

BTCBuy To design Cost

SE, GE of parts development, purchasing,

manufacturing, vendors

Cost reduction by design change

- Investment- Lead time

Loss


Page 12

DESIGN VALIDATION

Design LibraryBenchmarking

Component &Pretest Develop

ProductionPreparation

Concept studyInitial Design

Vehicle Initial Tuning- Hard Points- Specification & etc.

Abuse TestStructural Durability TestProto Spec. set-up

Concept Verification

Install & InstructionQuality ControlProductivity

Product Validation

Target StudyLay-out & PackageDynamic SimulationPerformance AnalysisFEM Analysis

Concept Develop

ADAMS

Abaqus

Mark II

Nastran

LS-Dyna

Auto Form

Pam-Crash

Design Verification

PrototypeDevelop

Vehicle Fine TuningProduction Spec. set-upDurability TestCost & Weight Control


Page 13

PRODUCT DEVELOPMENT SYSTEM – Computer-Aided Automotive Development (CADDS)

Layout Layout DrawingDrawing

Parts DesignParts DesignDrawingDrawing

Assembly Assembly DesignDesign

Harness DesignHarness Design& Layout& Layout

InterferenceInterferenceCheckingChecking

ComputerComputer--aided Designaided Design

CATIAStructural

Analysis (Linear)Crash-worthiness & Occupant Safety NVH

Computational Fluid Dynamics

Computer Aided Engineering and Virtual TestingComputer Aided Engineering and Virtual Testing

MSC-PATRAN LS-DYNA 3DADAMS

ProcessPlanning

DiesDesign

Assembly JigInspection Jig

NC TapeGeneration

StampingSimulation

RobotProgramming

Robot Simulation

Assembly LineSimulation

Computer Aided ManufacturingComputer Aided Manufacturing

AUTOCAD, CAD/CAM-CATIA/CADAM

Computer Aided Assembly/Robotic SimulationComputer Aided Assembly/Robotic Simulation

ROBCAD, WITNESS

Engineering DesignEngineering Design

ElectricalElectronics &EM Analysis

MSC-NASTRAN

Emission, Performance & Safety Anaechoic Chamber, Strength & Material

Laboratories, Sled Test RigSHSTT (Test Track),

Simulation Road Surface Track

Component Material

Homologation & TestingHomologation & Testing

Emission

EndurancePerformance CrashR&H

NVH

4-Poster Driving Simulation Rig, Kinematics Rig, Engine Dynamometer

ManufacturingManufacturing

*

Package Layout

Drawing

ErgonomicStudy

Animation & Design

Presentation

3D Modeling

Sketching&

Rendering

ConceptDesign

1:1 Clay1:1 BIW

DigitalMock-up

DMU

CATIA / Safeworks Maestro - SLA/LOM - Slice-LOM -Magic RP

Parts Digitising

& Modeling

ReverseEngineer-

ing

Product Analysis & Product Analysis & LearningLearningCATIA

Computer Aided Computer Aided Ergonomic StudyErgonomic Study Rapid PrototypingRapid PrototypingComputer Aided Industrial DesignComputer Aided Industrial Design

ALIASPaint; Auto Studio; Eclipse Composer

CATIA - Class ‘A’ Surfacing 5-Axis Milling Machine, Digitising

PRODUCT PLANNINGPRODUCT PLANNING STYLINGSTYLING PROTOTYPEPROTOTYPE

Suppliers / VendorSuppliers / Vendor--Modules/SystemsModules/Systems PowertrainPowertrain

RED

ESIG

NR

EDES

IGN


Page 14

PRODUCT DEVELOPMENT SYSTEM – NPI Integrating Activities Model

NEW PRODUCT DEVELOPMENT

STRATEGY

NEW PRODUCT DEVELOPMENT

STRATEGY

“SOFT” NPI ACTIVITIES

“SOFT” NPI ACTIVITIES

“HARD” NPI ACTIVITIES

“HARD” NPI ACTIVITIES

PEOPLEPEOPLE

TOOLS & TECHNIQUES

TOOLS & TECHNIQUES

PROCESSPROCESS

FORMAL METHODSFORMAL

METHODS

• Cross Functional Teams• Team Leadership• Team Development (Education &

Training)• Reward and Recognition Systems• Co-Location

• Cross Functional Teams• Team Leadership• Team Development (Education &

Training)• Reward and Recognition Systems• Co-Location

• Project Management• Formal NPI Procedures• Customer-Supplier Integration• Formal Team Briefings• Organization Re-Design

• Project Management• Formal NPI Procedures• Customer-Supplier Integration• Formal Team Briefings• Organization Re-Design

• Computer/Networks (Common Database)

• Computer-Aided Design (CAD)• Computer-Aided Engineering (CAE)• Computer-Aided Simulation (CAS)

• Computer/Networks (Common Database)

• Computer-Aided Design (CAD)• Computer-Aided Engineering (CAE)• Computer-Aided Simulation (CAS)

• Quality Function Deployment (QFD)• Design of Experiments (Taguchi)• Design for Manufacturing / Assembly

(DFM/DFA)• Failure Mode & Effect Analysis (FMEA)

• Quality Function Deployment (QFD)• Design of Experiments (Taguchi)• Design for Manufacturing / Assembly

(DFM/DFA)• Failure Mode & Effect Analysis (FMEA)


Page 15

PRODUCT DEVELOPMENT SYSTEM – NPI Process MILESTONES GATEWAYS

11-STEP PROCESS11-STEP PROCESS KEY CONTENTSKEY CONTENTS

INITIAL SCREENING KICK-OFF

INITIAL SCREENING INITIAL SCREENING KICKKICK--OFFOFF

PROJECT INITIATIONPROJECT INITIATIONPROJECT INITIATION

PROJECT DIRECTIONPROJECT DIRECTIONPROJECT DIRECTION

PROJECT (MODEL) FIXPROJECT (MODEL) FIXPROJECT (MODEL) FIX

PROJECT APPROVALPROJECT APPROVALPROJECT APPROVAL

PROJECT DESIGN APPROVAL

PROJECT DESIGN PROJECT DESIGN APPROVALAPPROVAL

PROJECT FINAL APPROVAL

PROJECT FINAL PROJECT FINAL APPROVALAPPROVAL

PRE-PRODUCTION APPROVAL

PREPRE--PRODUCTION PRODUCTION APPROVALAPPROVAL

PRODUCTION APPROVALPRODUCTION APPROVALPRODUCTION APPROVAL

LAUNCH APPROVALLAUNCH APPROVALLAUNCH APPROVAL

PROJECT CLOSUREPROJECT CLOSUREPROJECT CLOSURE

111

222

333

444

555

666

777

888

999

101010

111111

IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING “QUICK & DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO”

IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING “QUICK & DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO”

TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS

TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS

MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI

MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI

VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING

FINALIZATION INVESTMENT & RESOURCE FINALIZATION

VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING

FINALIZATION INVESTMENT & RESOURCE FINALIZATION

DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF

DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF

DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM)DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM)

ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. SEPCIFICATIONS

ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. SEPCIFICATIONS

PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION)

PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION)

MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION

MARKETING SIGN-OFF MARKET LAUNCHMARKETING SIGN-OFF MARKET LAUNCH

PROJECT CLOSURES ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNTKNOWLEDGE CAPTURING

PROJECT CLOSURES ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNTKNOWLEDGE CAPTURING

PHA

SE 0

PHA

SE 0

PHA

SE 1

PHA

SE 1

PHA

SE 2

PHA

SE 2

PHA

SE 3

PHA

SE 3

PHASEPHASE


Page 16

COMPLEX PRODUCTS WITH

CLEARLY DEFINED MARKET

REQUIREMENTS



REQUIREMENTS

SIMPLE PRODUCTS WITH


REQUIREMENTS

SIMPLE PRODUCTS WITH


REQUIREMENTS


DIFFICULT TO DEFINE MARKET

REQUIREMENTS


DIFFICULT TO DEFINE MARKET

REQUIREMENTS

SIMPLE PRODUCTS WITH DIFFICULT

TO DEFINE MARKET

REQUIREMENTS

SIMPLE PRODUCTS WITH DIFFICULT

TO DEFINE MARKET

REQUIREMENTS

FUNCTIONAL COMPLEXITY

STR

UC

TUR

AL

CO

MPL

EXIT

Y

INCREASING NEED FOR IN

TEGRATION ACTIVITIES

INCREASING INFLUENCE FOR 11-STEP PROCESS

PRODUCT DEVELOPMENT SYSTEM – NPI Process – Relationship with Product’s Complexities


Page 17

27 27 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Major freezeModel fix

3 M

PilotPRO

JEC

T α Styling

Mule Off tool Prototype

Production tooling M/T V/MShip

14 M

Detail design

ConceptInitiation

PRODUCT PROPOSAL

ConceptDirectionSTYLING

APPROVAL

ConceptApprovalMODEL

FIX

FinalApprovalDQCM

ProductionApproval

PQCM

MARKET

PRODUCT

INVESTMENT & COST

STYLING

DESIGN

PROTOTYPING

PROCUREMENT

PRODUCTION PREPARATION

QUALITY

Market Research

USPs

Total Cost & Investment

Styling Concept

D&E Overview

-

New, Mod. or C/Over

-

-

Homologation Plan

TESTING & VALIDATION

Volume-Price Justification

Teardown & B/Marking

BOM CostTarget

Packaging & Ergonomics

DCS & Layout

Mule Car Plan

Sourcing Strategy

Location & Layout

GD&T

Design Validation Plan

Focus Group

Development Schedule

BOM & Inv. Review

Surfacing & DMU

SE, DFMEA & PFMEA

Mule Car

Appoint &Cost Review

Process Plan

Quality Planning

Mule Car Test

Marketing Plan

CVDS

BOM & Inv. Tracking

Colors & Accessories

P-Drawings

Mule Car

Final Supply Cost

Process Validation

Process Control

Test Results & Validation

Sales & Launch Plan

Product Variants

OMV & OTR

-

PCR / PCO Cut-off

-

PPAP & PSWPSA

Final Process

Build-up Quality

Durability & Reliability

Pet Name, Brochures, Launching Program, 7 Manuals

Project Progress Follow-Up and Tracking

Project Feasibility Tracking(BOM & Investment)

Interior and Exterior Colors, Material, Texture Follow-up and Finalization

C.L. Tracking and Validation

Timely Feedback to Design, Manufacturing Engineering and Quality

Vendors / Suppliers Preparation Progress Follow-up

Contractors / Tools Suppliers Preparation Progress Follow-up, Line Training

• Validate Vendors Quality Systems• Validate In-House Quality Process

Timely Feedback to Design, Manufacturing Engineering and Quality

FOLLOW-UP and COUNTERMEASURES

SOP

PRODUCT DEVELOPMENT SYSTEM – NPI Process – Programme and Follow-Up


Page 18

27 27 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PRODUCT DEVELOPMENT SYSTEM – NPI Process –Manufacturing Engineering Initiatives

Major freezeModel fix

3 M

Pilot

StylingMule Off tool

Prototype

Production tooling M/T V/MShip

14 M

Detail design

SOP

Line Modification, Construction, Installation, Testing and Validation

1

2

3

4

PRO

JEC

T α

ConceptInitiation

PRODUCT PROPOSAL

ConceptDirectionSTYLING

APPROVAL

FinalApprovalDQCM

ProductionApproval

PQCMFOLLOW-UP and

COUNTERMEASURES

ConceptApprovalMODEL

FIX

Product Location Approval (including Investment)

Production Layout Finalization

Appointment of Contractor and Tooling (Dies and Jigs) Suppliers

M-Car Production Phased-out

Line Preparation Completion

Equipment and Facilities Relocation (including for Spare Parts)

Appointment of Local Vendors

SE (Simultaneous Engineering) for DFMEA &

PFMEA

CRITICAL MILESTONESINITIATIVES

FOR PRODUCTION

PREPARATIONFOR

Project α(Platform

Carry-Over)

PROJECT TO BE ABLE TO

BE LAUNCHED BY 18 MONTHS AFTER MODEL

FIX

Quality Planning (GD7T, Fit & Finish, Appearance, BIW, Warranty, Reliability)

Product and Process Quality5

Lessons Learnt and Improvement

Market & Production Quality Feedback

6


Page 19

Casting

Engine Design

Machining

Body Design• Chassis• Equipment• Electrical• CAE

• Noise Test• Vibration Test• Crash Test• Homologation

• Benchmarking• Market

Research• Gurun Alam Plant

• Bertam PlantPRODUCTPLANING STYLING

ENGINE

Rendering

Clay Modeling

ENGINEERING PROTOTYPE TESTING ASSEMBLYLOGISTICPRODUCTION PREPARATION

TYPICAL PROJECT –DEVELOPMENT MAN-HOUR and INVESTMENT

PRODUCTPLANNING

STYLING ENGINEER-ING

PROTOTYPE TESTING PROD.PREP.

LOGISTIC ASSEMBLY

MANHOUR

6 % 10 % 25 % 9 % 14 % 19 % 11 % 6 %

COST

1 % 2 % 22 % 11 % 6 % 51 % 5 % 2 %

Average ~ +/- 1.0 Million Man-hour

Average ~ RM 500 ++ Million


Page 20

PROGRESS MONITORING and DECISION MAKING

Require ‘top down’ and ‘bottom up’ process.

MECHANISM THE MANAGEMENT TEAM (MCM, PDC)

DECISION MAKING

PROBLEM IDENTIFICATION

PROBLEM RESOLUTION

PROBLEMESCALATION

PROVIDE STRATEGIC INTENT

PROVIDE GUIDANCE

MONITORING &CONTROL

IMPLEMEN-TATION

• Monthly Product / Project Committee Review Meeting.

• Management Committee Meeting

• Weekly Meeting

• Status Reports• Daily Meeting

THE PROJECT TEAM MEMBERS


Page 21

COMMON CAUSE OF FAILURES

%

57

39

35

34

29

26

20

17

13

12

11

4

0 10 20 30 40 50 60

Bad Communication between relevant parties

Lack of Planning of scheduling, resources andactivities

No quality Control

Milestone not being met

Inadequate coordination of resources

Costs getting out of hand

Mismanagement of progress

Overall poor management

Supplier skills oversretched

Supplier under resources

Insufficient measurable outputs

Supplier manpower not consistent

Source : The Bull Survey (IT Project)


Page 22

LESSONS LEARNT

• Care about everything and dwell on nothing.• Don’t wait to be told to do something.• Develop a keen understanding of human nature.• Learn the who, when and how to rely on others.• Consider technology, people and business when

making decisions.• Learn how to make decisions with ambiguous,

imperfect or incomplete information.• Never stop developing your social skills.• Appreciate the value of being politically savvy.


Page 23

THANK YOUFOR

YOUR ATTENTION