NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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.
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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.
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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)
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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)
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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COMPLEX PRODUCTS WITH
CLEARLY DEFINED MARKET
REQUIREMENTS
COMPLEX PRODUCTS WITH
CLEARLY DEFINED MARKET
REQUIREMENTS
SIMPLE PRODUCTS WITH
CLEARLY DEFINED MARKET
REQUIREMENTS
SIMPLE PRODUCTS WITH
CLEARLY DEFINED MARKET
REQUIREMENTS
COMPLEX PRODUCTS WITH
DIFFICULT TO DEFINE MARKET
REQUIREMENTS
COMPLEX PRODUCTS WITH
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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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)
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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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.
NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]
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THANK YOUFOR
YOUR ATTENTION