VW Audit Cheklist - Empty

DUNS-Nr.:

Rating scale first development (Tier 1): A = 90 - 100% Development capability fulfilled

B = 75 - 89% Development capability partially fulfilled

C = < 75% Development capability not fulfilled

Rating scale second development (Tier 2): incapable/capable

Assessment

Date:

Distributor:

Plastic parts for GM and Mazda

Pritzke, Jens (K-ES/B1)

Seite 1/5

Form responsibilitiy: Volkswagen AG, K-ES TE-Lieferantenbewertung, Brieffach 1446, 38436 Wolfsburg, DeutschlandChange status 01.11.2008 (A4-Format)

Poerksen, Maik (VWG Malaysia)

Che, Fong Mei (VWG Malaysia)

Werner, Thorsten (EKKF)

Raguse, Michael (EKP/Z)

Second Development

ProductsLocations/Development locations JV-Partner

Main plant Shah Alam, Selangor (MY)

Capable

Findings / Requirements / Highlights / Management informations

No of Employees

Technical Tie-up with Marui (since 2010)

(Global Sourcing)(Forward Sourcing)

Location information to suppliers

Corporate structure:

FE

648

Niedenfuehr, Sven (EKKF/2)

ASSY Door Trim

Armrest : >PES< 867-

Plastic Injection moulding >PP<

6RU

-

011C 74%

Component-related assessment of development partnerConsolidated Development Control, K-ESB

Lot 76 & 75A, Jalan Sementa 27/91, Section 27, 40000 Shah Alam, Selangor,Malaysia

Hicom Teck See Manufacturing Malaysia Sdn. Bhd.

652100793Potential analysis for localization

VW 250 G (RL IN)

Visit purpose:

Nazare, Anja (K-ESB)

Utzeri, Giancarlo (K-ES/B1)

Lauck, Joachim (K-ESB)

First DevelopmentPart number

Name, Organisation, Auditor Signature Name, Company Signature

Terence SOO Thean Hin (COO)Walenkamp, Gijs (K-ESB - TE-Auditor)

Audit Result

24.09.2010

Rayong plant(Thailand)

Tanjung Malim plant(MY)

210

Plastic parts23

Component/Product Group(with product technology)

Information to suppliers :-Hicom-Teck See belongs to 51% DRB-HICOM and 49% Teck See Plastic.

-Built in 1962 with a capital of ¡Ö RM260 Mil. In 2009 and 810 employees -Product Portfolio : Plastic parts (Instrument panel, bumper, door trim)

-Customer : Proton, Perodua (ca. 95% Tier 1) and Brose (Tier 2) 97 % Tier1 vs. 3 % Tier2 -Certification : ISO 9001 , ISO / TS 16949, ISO 14001

Management info for assessment results :The company HTS is currently classified as a typical manufacturing / Built-to-print supplier for plastic circumferences like instrument panel without

slush-OB, door trim and bumper. This company is in consideration as a potential supplier for a localization project of VW Polo G-Circumferences The company is able to produce based on customer data tools and set up appropriate production processes and carry out optimization loops

Significant own development skills are lacking. CAD and CAE expertise, testing facilities and material testing.

The project management is structured and based on customer specifications

Other differences: see report

Premise Procurement :

-Support through a TE-Wolfsburg engineering services

-Termination of the report illustrated weaknesses

-Introducing company/technical concept in operating department TE-Wolfsburg

The company was requested to eliminate the weaknesses as mentioned in the report, with a nomination by an action plan. Plant : Overview of test equipments, material safety data sheets, Chrome planning

Development Partner's Info

Customer

Part name: Part-Number.:-

6RU 867

(Emphasis [Sum 100%])

1. Specification and environment norm (2%)

2. Design and simulation system (17%)

3. Design capacity and skills (19%)

4. Technology und Product (4%)

5. Testing (19%)

6. Prototyping (15%)

7. Project competency/communication (12%)

8. Methods of project development (12%)

Result analysis:

Forward Sourcing 194

(new Product Design) 260*100

Global Sourcing(without new product design)

Participants:

Azmi Wahap (Manager Autom.Comp.&Eng. Division) Kainz, Thomas (QS-Auditor, Audi Ungarn)

Seite 2/5

If yes, from which supplier:

Selangor (Malaysia)

Sarly Adle Bin Sarkum (Head of Division Bus.Dev.)

No

Current Development Projects and Customers:

If the development partners already judged :

Component orProduct group

Technology

Rating result:Date:Middle group:Product:

capable

Judgement criteria for Project:

Total Result

New Product Design

(Forward Sourcing)

Remarks

Yes

Development location(s):

Contact person and position:

Experience cooperation in SE-Process

Proton, Perodua, Mazda, Honda…

Plastic parts in interior and exterior

Various -

Points180

VW 250 G (RL IN)

also with the participants from DRB-Hicom Headquarters

Sarly Adle Bin Sarkum (Head of Division Bus.Dev.)

Saw, David (VWG Malaysia)

Adam Mat Robi (Manager Project Development)

…

Walenkamp, Gijs (K-ESB - TE-Auditor)

Volkswagen AG

Yau Kian Min (Manager Bus.Dev. Division)

Terence SOO Thean Hin (COO)

Yohan bin Mokhtar (Senior Manager Veh.Man.Proj.)

Lim Sheng Shun (Senior Manager Prod. Planning)

Poerksen, Maik (VWG Malaysia)

Che, Fong Mei (VWG Malaysia)

Hicom Teck See Manufacturing Malaysia Sdn. Bhd.

Component-related assessment of development partner

Result =

74%Result = C

ASSY Door Trim

011

30 40 50 60 70 80 90 100

Performance level [%]

30 50 70 90

=max. 260 Points reachable

max. 230 Points reachableEvaluation criteria 2.3, 4. and 8.aare not included in the assessment

corresponds to Rating:

corresponds to Rating:

6R06RG

807853

221.D651

1. 0 5

2.

2.1 0 10

2.2 0 20

2.3 0 4 6 8 10

2.4 0 5.

.

3.

3.1 0 16 24 32 40

3.2 0 4 8 12 16

3.3 0 4 6 8 10

.

4. 0 4 6 8 10

.

Seite 3/5

Does the development partner possess design competency:

If 3.1 =< 24, has the development partner access/grasp to alternatives (foreign capacity):

(max. 50 Points)3. Result

1. and 2. Result

Does the development partner possess sufficient design capacity:

Design capacity and competency

DFÜ: Design data management system not available

VW-compliant data check module: End check & Validity: Catia V5 R19 not available

Points

o

Requirement not fulfilled

Requirement insufficiently fulfilled

Requirement generally fulfilled, deviation present

Requirement generally fulfilled, slight deviation

Requirement fully fulfilled


Cover front and back

ASSY Radiator Grille

Has the development partner all the required specifications and environment standard

Hicom Teck See Manufacturing Malaysia Sdn. Bhd.Assessment criteria for

Points

Points

Points

Points

Has the development partner CAD System compatibility acc. To VW AG (VW01059) and actual System guidelines

Yes, should: Catia V5 R19

CAE: Know-how limited availability, proposed amendment to optimise tooling come from tools supplier

Based on Class A-Surface-Data, component construction at OEM proton on site are performed by 3 of Hicom Teck See employees.

At visited headquarters: CAD Data and drawing management / dissemination at tools supplier

Employee qualification : current state matrix, without forecast

VW99000: available, content unknown

B2B access incl. ESL available, person responsible: Project manager

Catia V5 R18 an 19: 3 Licenses

B2B contents should be centrally file and all involved project to be provided

Design- and Simulation System

Has the development partner CAD Systems - if yes, state:

Plastic full simulation and warping: moldflow-analysis would be performed via tools manufacturer; Documentation available

FE Simulation to vehicle occupant protection (ECE, FMVSS, EuroNCAP), head impact, modal analysis and acoustic (NVH), misusage: all about OEM/Customers

Is the development partner using innovative Construction and Simulations method:

CAD-Data storage needs to be improved (Stucture, partial disk, CD-Rom)

Processes: Plactics IM, Blow Molding, no Slush or material after spraying, manual painting at location, using Robot in Thailand branch,

Chrome: currently external supplier, internal facility will be establish in 2011 (micropores)

Used weld technology I-Panel:US-welding (2x), HSK: Hot-Plate welding, no laser trimming or Waterjet available, manual trimming support plate door trim

Plastic: resin --> local resin supplier (see data sheet)

Technology and Product - Does development partner possess innovation potential

If yes, for which product, process or material:


Datas are exchanged using CD-ROM with OEM-customer (Proton)

Tools supplier (e.g Moltec, DongWang, Hanguk from Malaysia, Korea, Taiwan)

IDIADA (Spain): Head impact FEM-Analysis

Overall-design: 3Employees (CAD) / CAE: 0 Employee / Project management: 6 Employees as Programme manager plus 14 Product engineers

Has the development partner DFÜ (Data Transmission) and Data Check Module for drawing exchange

(max. 50 Points)

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6RU 867 011

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ASSY Door Trim

6RU 867 011

Points







ASSY Door TrimHicom Teck See Manufacturing Malaysia Sdn. Bhd.Assessment criteria for

Points

Points

Points

Points

5.

5.1

a) 0 8 12 16 20 1 -

b) 0 8 12 16 20 1 -

c) 0 8 12 16 20 1 -

d) 0 8 12 16 20 1 -

5.2

a) 0 8 12 16 20 1 -

b) 0 8 12 16 20 1 -

c) 0 8 12 16 20 1 -

0 8 12 16 20 1 -

5.3

a) 0 8 12 16 20 1 -

b) 0 8 12 16 20 1 -

c) 0 8 12 16 20 0

d) 0 8 12 16 20 0

-

5.4 0 20

5.5 0 4 8 12 16

5.6 0 4 6 8 10

-

6.

6.1 0 8 12 16 20

6.2 0 20

6.3 0 4 8 12 16

-

If 5.4 = 0, has the development partner access to alternative (foreign capacity):

The development partner has sufficient testing competency:

external Institute : e.g. TÜV Singapore, IDIADA, local OEM Proton

Testing

Has the development partner appropriate test capabilities for functional testing: Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)

Block 5.3 = (Sum of a+b+c+d) / (No. a+b+c+d) Has the development partner appropriate laboratory equipment and instrumentation:

Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d) Has the development partner appropriate test capabilities for continuous testing :

EP 85550.30: Ball drop test on loudspeaker grill (M=0,5 kg RT-10°C, PV3905) --> external institute or OEM

EP 85550.70: Misuse by forces up 500 N on mesh, door tray box under RT-30+70°C --> external institute or OEM

Present : Gauges.

EP 84610.21: continuous load of arm rest and door handles (steel ball, 150 N, N=10000, -30+70°C) --> external institute or OEM

EP 84110.01: Push in / push out forces / Tear off test of fasteners (RT) --> external institute or OEMEP 84610.10: Function Test: load on arm rest / door tray --> external institute or OEM

EP 84610.12 /EP85550.22: Buckling resistance of trim panel and door tray (RT,+70°C)

EP 84610.50: Temperature aging +LF--> climate chamber (-30+100°C+LF, 48h) -> 1x Climate chamber (-30+177°C+LF) EP 84610.51: climatic cycle---> climate chamber (PV2005) -> 1x Climate chamber (-30+177°C+LF)

EP 85550.10: Door closing Function test by pulling on tray (150N, -30+70°C, N=1000) --> external institute or OEM

High temp. lightfastness (PV1303, 5 cycles, 100 °CXenontest=solisi) --> external institute or OEM

Present : Dimension, Weight, Measuring table, auto. 3D measuring machine (unexact, +/- 0.1 mm). External : Flammability (TL1010)

Material e.g PP : Emission behaviour, Fogging (VW 50180), density, yield stress, elongation, ball indenation hardness, melting temp.…

Continuous monitoring relevant : Present --> Glossmeter

Checking gauge in plastic plant : Present --> Single part and Assy

Significant amounts are performed externally

Ergebnis = (Summe aus den Blöcken 5.1+5.2+5.3) / (Anzahl der Blöcke)

Has the development partner sufficient testing capacity:

Prototyping

(max. 40 Points)6. Results

If 6.2 = 0, has the development partner access to alternative (foreign capacity):

Has the development partner sufficient prototyping capacity:

Has the development partner an adequately equipped and organizationally independent prototyping:

Documentation as per PPAP-Document (Measuring report, test report)

Present : Detailed testing plan, testing specification and documentation

Present : Calibrated and documented measuring devices / no temperature controlled measuring room

Organizationally not independent. Plastic parts are manufactured on original equipment, assembly and construction prototypes in production

Suppliers of component parts

Gauges are used for measuring test part

1 room for master sample storage

Manufacturing and supplier for single part

(max. 50 Points)5. Results

Seite 4/5

Hicom Teck See Manufacturing Malaysia Sdn. Bhd.Assessment criteria for

Points

Points

Points

Points

6R06RG

807853

221.D651

Points






Component-related assessment of development partner Cover front and back

ASSY Radiator Grille

7.

7.1 0 10

7.2

0 4 6 8 10

7.3 0 4 6 8 10

7.4 N J

.

8.

0 4 6 8 10

0 4 6 8 10

0 4 6 8 10

8. Result (max. 30 Points)

9.

Remarks

Seite 5/5

- Advance know how product development methods (D-FMEA, QFD, DOE)

- Implement capacity planning

- Expansion of test facilities according to part testing specification (Special climate chamber, -40 ° C

/ upgrading auto. measuring machine including Scanpack / material analysis)

- Advance their know how in terms of FEM-methods

- Improve CAD-data storage

(max. 260 Points)Assessment Result


Can the development partners set schedules with milestones and resource allocation

Is direct communication (without translation) possible:

and ensure the execution of changes

Project competency / Communication

Processes and to PM clearly defined / structured customized centralized project storage at the server / schedules using MS Project Milestones customer, without critical path

with filling) / Open-point list available

For under development project, project rooms are set up (currently as Proton, Honda)

c) DOE Methods:

b) Design-FMEA:

a) QFD Methods:

English

Is it possible to carry out a development at customer's premises

Is the development partner applying the QM methods

Methods of product development

currently not implemented

QFD not shown in action,part of the circumference in the form of benchmarking by means of various examples

currently no D-FMEA (---> Built-to-print Supplier)iP-FMEA content in order including derivation process monitoring

.

An improvement plan must be presented upon nomination within 14 days after receiving of this report.

In addition the supplier was informed that the next TE capability audits and project-specific performance rating be pronounced by the department.

- Study the contents of B2B-Portal (Supplier manual, norm portal, VW99000…)

- Advance their know how in terms of component design and tool-based design (plastic parts, steering wheel frame)

- Ensure access to KVS

-

At regular time intervals (agreed with the department) significant schedules, to-do lists and meeting of minutes should be provided. .

The company was advised that a pro-active communication is required with the operating department

The project organization (organization, contact person, position and contact information) is to be presented (including any changes) at initial project.

- Improvements in production samples (space, processes, storage, workstations, packaging ...)

The company is requested to resolve the following weaknesses:

Project teams through cross-functional teams in writing and communicated to client

Currently no Resident Engineer near Wolfsburg

No holistic resource planning across projects /

Change Management: Process standard exists, change pass transparent and complete.

Can the development partners set project structures with a responsible project leader:

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6RU 867 011

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ASSY Door Trim

Documents

VW Audit Cheklist - Empty