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Globalization of NPW (Nissan Production Way)
Introduction of Global Training Center
Globalization of NPW (Globalization of NPW (NNissanissan PProductionroduction WWayay))
Introduction of Introduction of GGlobal lobal TTraining raining CCenterenter
Nissan Motor Co. Nissan Motor Co. EVP Tadao TakahashiEVP Tadao Takahashi
November 29November 29thth, 2006, 2006
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• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
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Nissan Production Way : Two never ending
Never ending quests to identify problemsNever ending quests to identify problemsand put in place solutionsand put in place solutions
Never ending synchronization (Douki) Never ending synchronization (Douki) our manufacturing with the customersour manufacturing with the customers
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• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
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Globalization of production
OverseasJapan
(k units)
0
500
1,000
1,500
2,000
2,500
3,000
3,500
1940
1945
1950
1955
1960
1965
1970
1975
1980
1985
1990
1995
2000
2003
2004
2005
4,500
4,000
5,000
2003 : Over 50 %2003 : Over 50 %2003 : Over 50 %
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Vehicle plant ( Including KD ) : 27
Power Train plant : 25
Vehicle plant ( Including KD )( Including KD ) : 27 : 27
Power Train plant : 25: 25
Introduction of Nissan Motor
NNA Smyrna
Cuernavaca
NSA
NMUK
NMISAZNA
Huadu
DFLXiangfan
SNATCMA
MEGA
YL
NMPI
CantonNMEX Aguascalientes
NMI
TochigiOppama
Nissan ShataiKyushu
R de B
NEG
Knock DownComplete Build-up Unit
NMGR
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’50s 2000
Japan
NAFTA
ASIA
AFRICA
’70s ’80s ’90s’60s
Europe SpainUK
YokohamaNissan Shatai Oppama
IwakiTochigi
Kyushu
MexicoUSA
Mercosur
South Africa
‘05NPW ‘94
IndonesiaChina
Brazil
Egypt
ThailandTaiwan
Global plant launching history
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FY05 FY06 FY07
Japan
NAFTA
Europe
China
ThailandGOM others
70 new model launches in Nissan Value-Up
42/70
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1.912.00 2.01 2.02 2.03 2.07
1.82
2.152.25 2.31 2.33 2.38
2.462.54
2.60 2.61 2.62
2.78 2.80
2.96
0.00
1.00
2.00
3.00
4.00
K12 D21 N16 B15 N16 P12 D22 K12 Y11 A33 Y10 B15 L31 R20 V10 R50 D22 Y34 P12 C24
(UK) (MEX) (W) (W) (UK) (UK) (NS) (T) (NS) (T) (MEX) (MEX) (US) (MIS) (MIS) (W) (US) (M) (W) (M)
MATERIAL HANDLINGKAIZEN & TRAININGFOREMANDOWN-TIMECHECK & REPAIRDIRECT OPERATIONExcept KAIZEN & MATERIAL HANDLING
Common Common indexindex
As comparing performance globally,Best Practices are exchanged.
As comparing performance globally,Best Practices are exchanged.
Internal benchmarking
Best PracticeBest Practice Best practiceBest practice
Internal benchmarking
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Multi-model mixed production Example from body welding line
Standardization of hardware :NIMS (Nissan Integrated Manufacturing System)
Additional modelsHalve lead timeHalve investment
Jig part
NC locator part
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Overseas support : 3G + 1 strategies
Improve ManufacturingCapability
Trial Start of production
Launching Support
Centralized New Model Trial
Global TrainingCenter
Global ProductionEngineeringCenter
Global LaunchingExpert
Global PackageDesignCenter
3 GStrategies
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• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
• Nissan Production Way (NPW)
• New Challenge for Globalization
• Global Human Resources Development: GTC
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Power Train MfgMaintenanceVehicle MfgLogistics
Quality Assurance
JobCategory
50 members5,000㎡
Oppama
5 members225㎡
Yokohama
10 membersCapacity1,300㎡Area
Oppama
Yokohama
Overall of GTC
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Genba kanriSkill
CommonCastingMachine
Engine Assy
Material handlingQA
EquipmentMainte-nance
Powertrain
FutureManufac-turing
Press die
Vehicle
Course expansion
Course expansion
Main training courses
Basic skill
Basic skill
Advanced skill/ application skill
Advanced skill/ application skill
Daily m
anagement
Daily m
anagement
New
model m
anagement
New
model m
anagement
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14 Regions
Globally standardized “Training Way”
‥
‥
‥
‥
Global Master Trainer
NMUKNMISA NNA OTHER NML
‥RTC RTC RTC RTC GTC
B20DFL
RTC
NSA
RTC
SNA
RTC
NPW office
NPW office
NPW office
NPW office
NPW office
NPW office
NPW office
Basic skills
Advancedskills
--
--
Master Trainer System
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GG--Master TrainerMaster Trainer
Master TrainerMaster Trainer
Regional trainerRegional trainer
OperatorOperator
OverseasRTC
(Regional Training Center)
OverseasRTC
(Regional Training Center)
JapanGTC
JapanGTC
Human resources development through master trainer system
20 people (Nov ‘06)
Global “human resources” development through master trainer
Global “human resources” development through master trainer
20 times speed as conventional way (direct training)20 times speed as conventional way (direct training)
138 people (Nov ‘06)
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USUSUS
MexicoMexicoMexico
ChinaChinaChina
IndonesiaIndonesiaIndonesia
ThailandThailandThailand
South AfricaSouth AfricaSouth Africa
SpainSpainSpain
UKUKUK
JapanJapanJapan
Introduce best practices of training materials to all plants in the world
Introduce best practices of training materials to all plants in the world
Globally standardized “Teaching Material ”
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E.g. RTC in Thailand
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“Language” barrier““LanguageLanguage”” barrierbarrier
StandardStandardOperationOperationSheetsSheets
Hoja deHoja deOperacionOperacionEstandarEstandar
⇒ No language : Visual Manual⇒⇒ No language :No language : Visual ManualVisual Manual
Global human resources development Keyword : Visualization”
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Correct procedure and key points are visualized.Correct procedure and key points are visualized.
Visual Manual
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21113838 Master trainers were born.Master trainers were born.
History of courses (No. of master trainers as of Nov. ’06)
JanJan’’0606
Quality Quality AssuranceAssurance
Material Material HandlingHandling
MainteMaintenancenance
PowertrainPowertrainMFGMFG
Vehicle Vehicle MFGMFG
TTLTTLNovNovOctOctSepSepAugAugJulJulJunJunMayMayAprAprMarMarFebFebDecDecOctOct’’
0505
Mexico
5
Thailand
4
China
4
SpainMexico
US
9 34
South A
frica
3
UK
5
China
9 3
Egypt 9797
Mexico
4
Japan
1110
Mexico
2
China
2Indonesia
4
Indonesia
2
US
4
Mexico
3China
3Indone
sia3
China
2
Japan
4
Japan
China
6
88
1414
44
1515
Mexico
2
4
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Nissan Manufacturing Nissan Manufacturing Sprit to be WorldwideSprit to be Worldwide