Seminar Presentation Design Excellence For Manufacturing Sustainability V1

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  • Its an excellent presentation. since i’m a fresh graduated as well new in the malaysian automotive industry, this information enable me to get better understanding the importance on excellence design especially in automotive development. Manufacturing process rely on design aspect. Designers should have manufacturing knowledge in mind before they started to design a model.

    -Muhamad Fuady (Miyazu (M) Sdn Bhd)
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Seminar Presentation Design Excellence For Manufacturing Sustainability V1

  1. 1. Kamarulzaman Darus PJN Director of Manufacturing NAM Design Excellence for kzamandarus@nam.com.my +6012-277-2059 Manufacturing Graduated in B.Sc. Mechanical Engineering from Sustainability Leeds University, UK. Had been in the Automotive Manufacturing Business for more than 25 years. Had been responsible in key areas of Production and Planning, Manufacturing Engineering, Plant Engineering, Product Research and Development. Currently, the Director of Manufacturing – responsible in all aspects of Manufacturing for Naza Automotive Manufacturing. NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 1 [Company No.: 591026-M]
  2. 2. MALAYSIA’S INDUSTRIALIZATION MASTER PLAN Industrial Master Plan (IMP) Industrial Master Plan 2 1986 - 1995 (IMP2) Three broad objectives: 1996 - 2005 Moving beyond • Ensure rapid expansion of the economy through manufacturing operations acceleration of to include : manufacturing sector • Indigenous R&D and growth technology • Promote efficient and • Design Capabilities optimum utilization of • Integrated supporting natural resources through industries value-added manufacturing activities • International marketing • Development of own Brand • Lay foundation for the • World class, world scale development of indigenous technological capabilities “MANUFACTURING” “MANUFACTURING ++” We are now in the midst of IMP-3, which is basically a continuation of IMP-2 but focusing more on state-of-the-art technology and research such as nano- and bio-technology etc. NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 2 [Company No.: 591026-M]
  3. 3. INDUSTRY CAPABILITIES TRANSFORMATION MANUFACTURING DESIGN & ENGINEERING VIRTUAL PRODUCT VPDM DESIGN & MANUFACTURING MILEAGE ACCUMULATION MACD CHASSIS DYNAMOMETER Local Vendors Development Climatic Chamber, Engine Test Cells) CMSS (4-Poster, Kinematics Rig, (4- Crash Sled, Components Tests Laboratory) PROTOTYPING - Rapid Prototyping (SLA, LOM) , Prototyping Centre CADDS (Computer-Aided Design System) CAD (EUCLID, (Computer- Note: CATIA ® ), CAE, CAM Major Tests and Validations would still be STYLING, MODELING & ERGONOMICS Conducted in Tests Centers such as at Millbrook, Idiada, Crashlab etc. SHTT (Semi-High Speed Test Track), Emission and (Semi- Noise Laboratory (Semi-Anechoic Chamber) (Semi- CASTING and MACHINING DIES DESIGN & MANUFACTURING ENGINE ASSEMBLY JIGS DESIGN & MANUFACTURING STAMPING & DIES MAINTENANCE CAR ASSEMBLY OPERATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 NAZA AUTOMOTIVE MANUFACTURING SDN BHD 1986 2007 Page 3 [Company No.: 591026-M]
  4. 4. INDUSTRY DIFFERENTIATORS • Product Life Cycle •Platform Engineering •Short Lead Time from halved •Modular Engineering Ordering to Delivery • SE/CE Teams • CAS/CAD/CAE; VR Reduced Reduced Product Variety Marketing Product Product Variety Marketing Product Lifecycle Lifecycle INTEGRATED BY THE NPI SYSTEM INTEGRATED BY THE NPI SYSTEM Market & Market & Consumer Consumer DESIGNED FOR THE MARKET DESIGNED FOR THE MARKET Lower Volume ““Real-Time” Real-Time” Lower Volume Automation Automation Wider Range Logistics Wider Range Logistics • Flexible •EDI, JIT Manufacturing CAD / CAM / CIM •Configurable BOM System (FMS) KEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAIN KEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAIN NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 4
  5. 5. VALUE CHAIN TOOLING: COMMON STAMPING DIES, TESTING PLATFORM PLASTIC MOULDS & PLATFORM DESIGN & DEVELOPMENT VALIDATIONS ENGINEERING STAMPING BODY WELDING AND ASSEMBLY STYLING PRODUCT DESIGN ENGINEERING INTEGRATED AND DIFFERENTIATED BY PAINTING TECHNOLOGY (DESIGN & ENGINEERING) FINAL ASSEMBLY PRODUCT LOGISTICS & VENDORS DISTRIBUTION COMPONENT MARKET DEVELOPMENT (SALES & and SUPPLY MARKETING) & POWERTRAIN EQUIPMENT DESIGN & SUPPLIERS MANUFACTURING NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 5
  6. 6. INDUSTRY LEVEL OF CAPABILITIES SUSTAINABLE MANUFACTURER ….. ECONOMIES OF SCALE ~ MINIMUM 30K/MODEL/ YEAR GLOBAL QUALITY PRODUCTION ORGANISA- ORGANISA- QUALITY CONSUMER MARKET BRANDING PRODUCT SYSTEM TION COMPONENT Loyal Consolidated •“Own” Car •Low Cost •“Flexible” •Knowledgeable •Strong Brand •Global & •Competitive •“Own” Brand •Desirable •‘0’ Defect •Up-to-date Up- to- •Delighted Regional •Global Source •Up-to-Date Up- to- •‘0’ Stock Information Network COMPLETE MAKE TO ADVANCED SUITE FULL RANGE VENDOR FLEXIBLE CUSTOMERS’ GLOBAL MANAGEMENT OF DESIGN MODEL PARTNERSHIP PRODUCTION CONFIGURED MARKETING •Empowerment TOOLS DESIGN (1st TIERING) SCHEDULING ORDERS •Teams & FACILITIES (INCLUDING VR) GLOBAL SOUND TIMELY, MAKE PRESENCE MATERIAL ACCURATE, TO ‘IN-HOUSE’ IN- DEEP DESIGN INTEGRATED •Selected PROCESS AND ORDER DESIGN COMPETENCE SUPPLY CHAIN Markets FLOW INTEGRATED •Strong in •JIT, CC INFORMATION ASEAN •KANBAN MULTI PLANT SOUND ASSEMBLE GOOD OPERATIONS BASIC CROSS MATERIAL PROCESS TO PRODUCTION •Own MODIFICATION FUNCTIONAL COST and CONTROL DISTRIBUTORS’ SYSTEM •Contract DESIGN DESIGN TEAMS MANAGEMENT •Financial ORDERS •Process design •CKD •HR ASSEMBLE BASIC DESIGN SIMPLE DOMESTIC PARTNER VENDOR BASIC TO TOOLS PRODUCTION DOMINANCE DESIGN DEVELOPMENT FUNDAMENTAL STOCK AND FACILITIES SYSTEM NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 6
  7. 7. CAPABILITY DEVELOPMENT IP Value Chain S) High Technology High Employment e D siv High Knowledge Application N es FU gr ro T P EN 1:10 = 100,000 M OWN US J PRODUCT AD DESIGN L RIA RnD CENTRE T US & e iv D ss (IN ENGINE MFG e gr F Re IA 1:6 = 40,000 PLATFORM MFG R&D Centre, Product Design, Assemble Powertrain & Localize High Tooling 60% Labor Manufacturing . 1:1 = 600 CKD 25 years NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 7
  8. 8. PRODUCT DEVELOPMENT ELEMENTS EFFECTIVE DESIRED INITIATIVES DELIVERABLES MARKET BOARD Project Process Management Engineering Cost Vehicle Simultaneous Design Weight Plant Design, Engineering Engineering Set-Up & Development Quality Performance Engineering Machinery, Delivery Simulation Equipment & Analysis & Facilities TOTALLY INTEGRATED PRODUCTS MANAGEMENT IMPLEMENTATION NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 8
  9. 9. ADVANCED VIRTUAL ENGINEERING Design Safety Structural Style ST Control Performance Presentation CO Dynamic Formability Assembly & Performance Possibility G Possibility IN TIM NT Quality E Control PM O 3D CAD EL Modeling V DE Crash Durability Virtual G Simulation Analysis IN Reality C Vehicle DU Metal Dynamics RE Digital Forming Analysis Analysis Mock Up Tolerance Analysis NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 9
  10. 10. CONCURRENT ENGINEERING To shorten the development time and reduce the cost of late design changes through early involvement of all stakeholders during development The desired CAE No of design change Mule vehicle The historic Alias styling Verification model Formability DMU More cost for design change and market warranty Planning Styling Proto Pilot Prod. S.O.P NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 10
  11. 11. COST CONTROL & BENCHMARKING PAST Present Estimated Estimated Design Design sales price sales price Target cost Parts develop. Target cost Parts develop. set up Purchasing set up Purchasing DTC Manufacturing Manufacturing Design To target Cost Cost totaling Cost totaling BTC Buy To design Cost Sales price Sales price SE, GE of parts Cost reduction by development, design change purchasing, - Investment manufacturing, vendors - Lead time Loss NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 11
  12. 12. DESIGN VALIDATION Concept Product Verification Validation Vehicle Initial Tuning Install & Instruction - Hard Points Quality Control - Specification & etc. Productivity Abuse Test Structural Durability Test Proto Spec. set-up Design Library Concept study Component & Prototype Production Benchmarking Initial Design Pretest Develop Develop Preparation Design Verification Concept Develop Target Study Vehicle Fine Tuning Lay-out & Package Production Spec. set-up Dynamic Simulation Durability Test Performance Analysis Cost & Weight Control FEM Analysis LS-Dyna Abaqus Pam-Crash Auto Form Nastran ADAMS Mark II NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 12
  13. 13. PRODUCT DEVELOPMENT SYSTEM – Computer-Aided Automotive Development (CADDS) PRODUCT PLANNING STYLING PROTOTYPE Package Sketching Animation & Digital Ergonomic Concept 3D 1:1 Clay Layout & Design Mock-up Study Design Modeling 1:1 BIW Drawing Rendering Presentation DMU Computer Aided Computer Aided Industrial Design Rapid Prototyping Ergonomic Study ALIAS Maestro - SLA/LOM - Slice- CATIA / Safeworks Paint; Auto Studio; Eclipse Composer LOM -Magic RP Parts Reverse 5-Axis Milling Machine, CATIA - Class ‘A’ Surfacing Digitising Engineer- Digitising & Modeling ing Suppliers / Vendor- Vendor- Powertrain Product Analysis & Modules/Systems Learning CATIA Homologation & Testing Engineering Design Layout Parts Design Assembly Harness Design Interference Component NVH Emission Material Drawing Drawing Design & Layout Checking Endurance REDESIGN * R&H Computer-aided Design Computer- Crash Performance CATIA Emission, Performance & Safety Electrical Anaechoic Chamber, Strength & Material Computational Structural Crash-worthiness Electronics & NVH Laboratories, Sled Test Rig Fluid Dynamics Analysis (Linear) & Occupant Safety EM Analysis SHSTT (Test Track), Simulation Road Surface Track Computer Aided Engineering and Virtual Testing 4-Poster Driving Simulation Rig, MSC-PATRAN MSC-NASTRAN ADAMS LS-DYNA 3D Kinematics Rig, Engine Dynamometer Manufacturing Robot Robot Assembly Line Process Dies Stamping NC Tape Assembly Jig Programming Simulation Simulation Planning Design Simulation Generation Inspection Jig Computer Aided Assembly/Robotic Simulation Computer Aided Manufacturing ROBCAD, WITNESS AUTOCAD, CAD/CAM-CATIA/CADAM NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 13
  14. 14. PRODUCT DEVELOPMENT SYSTEM – NPI Integrating Activities Model • • Cross Functional Teams Cross Functional Teams • • Team Leadership Team Leadership • • Team Development (Education & PEOPLE Team Development (Education & PEOPLE Training) Training) • • Reward and Recognition Systems Reward and Recognition Systems • • Co-Location “SOFT” NPI Co-Location “SOFT” NPI ACTIVITIES ACTIVITIES Project Management • Project Management • Formal NPI Procedures • Formal NPI Procedures • PROCESS Customer-Supplier Integration PROCESS • Customer-Supplier Integration • Formal Team Briefings • Formal Team Briefings • Organization Re-Design • Organization Re-Design • NEW PRODUCT NEW PRODUCT DEVELOPMENT DEVELOPMENT STRATEGY STRATEGY Computer/Networks (Common • Computer/Networks (Common • Database) Database) TOOLS & • Computer-Aided Design (CAD) TOOLS & • Computer-Aided Design (CAD) • Computer-Aided Engineering (CAE) TECHNIQUES • Computer-Aided Engineering (CAE) TECHNIQUES • Computer-Aided Simulation (CAS) • Computer-Aided Simulation (CAS) “HARD” NPI “HARD” NPI ACTIVITIES ACTIVITIES • Quality Function Deployment (QFD) • Quality Function Deployment (QFD) • Design of Experiments (Taguchi) • Design of Experiments (Taguchi) FORMAL • Design for Manufacturing / Assembly FORMAL • Design for Manufacturing / Assembly (DFM/DFA) METHODS (DFM/DFA) METHODS • Failure Mode & Effect Analysis (FMEA) • Failure Mode & Effect Analysis (FMEA) NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 14 [Company No.: 591026-M]
  15. 15. PRODUCT DEVELOPMENT GATEWAYS MILESTONES SYSTEM – NPI Process PHASE 11-STEP PROCESS KEY CONTENTS PHASE 11-STEP PROCESS KEY CONTENTS INITIAL SCREENING IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING “QUICK & 1 INITIAL SCREENING IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING PHASE 00 “QUICK & DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO” 1 KICK-OFF KICK- DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO” KICK-OFF PHASE TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & 2 PROJECT INITIATION TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & 2 PROJECT INITIATION RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT 3 PROJECT DIRECTION PHASE 11 MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT 3 PROJECT DIRECTION & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI PHASE & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION 4 PROJECT (MODEL) FIX TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING 4 PROJECT (MODEL) FIX TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING INVESTMENT & RESOURCE FINALIZATION FINALIZATION INVESTMENT & RESOURCE FINALIZATION FINALIZATION DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + 5 PROJECT APPROVAL DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + 5 PROJECT APPROVAL SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF PROJECT DESIGN 6 PROJECT DESIGN DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM) 6 APPROVAL DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM) APPROVAL PHASE 22 PHASE PROJECT FINAL ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. 7 PROJECT FINAL ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. 7 APPROVAL SEPCIFICATIONS APPROVAL SEPCIFICATIONS PRE-PRODUCTION PRE- PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, 8 PRE-PRODUCTION PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, 8 APPROVAL SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION) APPROVAL SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION) 9 PRODUCTION APPROVAL MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION 9 PRODUCTION APPROVAL MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION PHASE 33 MARKETING SIGN-OFF 10 LAUNCH APPROVAL MARKET LAUNCH PHASE MARKETING SIGN-OFF 10 LAUNCH APPROVAL MARKET LAUNCH ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNT PROJECT CLOSURES 11 PROJECT CLOSURE ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNT PROJECT CLOSURES 11 PROJECT CLOSURE KNOWLEDGE CAPTURING KNOWLEDGE CAPTURING NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 15 [Company No.: 591026-M]
  16. 16. PRODUCT DEVELOPMENT SYSTEM – NPI Process – Relationship with Product’s Complexities COMPLEX PRODUCTS COMPLEX PRODUCTS STRUCTURAL COMPLEXITY WITH S WITH IE IT CLEARLY DEFINED IV CLEARLY DEFINED CT MARKET COMPLEX PRODUCTS MARKET COMPLEX PRODUCTS A N REQUIREMENTS WITH REQUIREMENTS TIO WITH DIFFICULT TO DEFINE A DIFFICULT TO DEFINE R EG MARKET T MARKET IN REQUIREMENTS R REQUIREMENTS FO D EE S N ES NG C RO SI P A RE P TE C -S IN SIMPLE PRODUCTS 11 SIMPLE PRODUCTS WITH R WITH FO CLEARLY DEFINED E CLEARLY DEFINED C EN MARKET MARKET U FL REQUIREMENTS SIMPLE PRODUCTS REQUIREMENTS SIMPLE PRODUCTS IN WITH DIFFICULT G WITH DIFFICULT IN S TO DEFINE EA TO DEFINE R MARKET C MARKET IN REQUIREMENTS REQUIREMENTS FUNCTIONAL COMPLEXITY NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 16 [Company No.: 591026-M]
  17. 17. PRODUCT DEVELOPMENT SYSTEM – NPI Process – Programme and Follow-Up 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 Model fix SOP PROJECT α Styling Major freeze Mule Off tool Prototype Detail design Production tooling Pilot M/T Ship V/M 3M 14 M Concept Concept Concept Production Final FOLLOW-UP and Initiation Direction Approval Approval Approval PRODUCT STYLING MODEL COUNTERMEASURES PQCM DQCM PROPOSAL APPROVAL FIX Marketing Sales & Market Volume-Price Pet Name, Brochures, Launching Program, 7 Focus Group MARKET Plan Launch Plan Research Justification Manuals Teardown & Development Product PRODUCT USPs CVDS Project Progress Follow-Up and Tracking B/Marking Schedule Variants INVESTMENT & Total Cost & BOM Cost BOM & Inv. BOM & Inv. Project Feasibility Tracking OMV & OTR COST Investment Target Review Tracking (BOM & Investment) Styling Packaging & Surfacing & Colors & Interior and Exterior Colors, Material, Texture STYLING - Concept Ergonomics DMU Accessories Follow-up and Finalization SE, DFMEA & PCR / PCO DESIGN D&E Overview DCS & Layout P-Drawings C.L. Tracking and Validation PFMEA Cut-off Timely Feedback to Design, Manufacturing PROTOTYPING - Mule Car Plan Mule Car Mule Car - Engineering and Quality TESTING & Homologation Design Mule Car Test Results Durability & Timely Feedback to Design, Manufacturing VALIDATION Plan Validation Plan Test & Validation Reliability Engineering and Quality New, Mod. or Sourcing Appoint & Final Supply PPAP & PSW Vendors / Suppliers Preparation Progress PROCUREMENT C/Over Strategy Cost Review Cost PSA Follow-up PRODUCTION Location & Process Final Contractors / Tools Suppliers Preparation - Process Plan PREPARATION Layout Validation Process Progress Follow-up, Line Training Quality Process • Validate Vendors Quality Systems Build-up QUALITY - GD&T Planning Control • Validate In-House Quality Process Quality NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 17
  18. 18. PRODUCT DEVELOPMENT SYSTEM – NPI Process – Manufacturing Engineering Initiatives 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 SOP Model fix PROJECT α Styling Major freeze Mule Off tool Prototype Detail design Production tooling Pilot M/T Ship V/M 3M 14 M Concept Concept Concept Production Final FOLLOW-UP and Initiation Direction Approval Approval Approval PRODUCT STYLING MODEL COUNTERMEASURES PQCM DQCM PROPOSAL APPROVAL FIX Product Location Line Preparation 1 Approval (including Completion Investment) CRITICAL Production Layout M-Car Production MILESTONES 2 Finalization Phased-out INITIATIVES FOR Equipment and Facilities Relocation (including PRODUCTION Appointment of for Spare Parts) PREPARATION FOR Contractor and Tooling 3 Project α (Dies and Jigs) Suppliers Line Modification, Construction, Installation, Testing and (Platform Validation Carry-Over) SE (Simultaneous Appointment of 4 PROJECT TO Engineering) for DFMEA & Local Vendors BE ABLE TO PFMEA BE LAUNCHED BY 18 MONTHS Quality Planning (GD7T, Product and 5 AFTER MODEL Fit & Finish, Appearance, Process Quality BIW, Warranty, Reliability) FIX Market & Lessons Learnt and 6 Production Quality Improvement Feedback NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 18
  19. 19. TYPICAL PROJECT –DEVELOPMENT MAN-HOUR and INVESTMENT Rendering Body Design • Benchmarking Clay Modeling • Chassis • Noise Test • Market • Gurun Alam • Equipment • Vibration Test Research Plant • Electrical • Crash Test • Bertam Plant • CAE • Homologation PRODUCT PRODUCTION STYLING ENGINEERING PROTOTYPE TESTING LOGISTIC ASSEMBLY PLANING PREPARATION ENGINE Engine Design Machining Casting PRODUCT STYLING ENGINEER- PROTOTYPE TESTING PROD. LOGISTIC ASSEMBLY PLANNING ING PREP. MAN Average ~ +/- 1.0 Million Man-hour HOUR 6% 10 % 25 % 9% 14 % 19 % 11 % 6% Average ~ RM 500 ++ Million COST 1% 2% 22 % 11 % 6% 51 % 5% 2% NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 19
  20. 20. PROGRESS MONITORING and DECISION MAKING Require ‘top down’ and ‘bottom up’ process. MECHANISM THE MANAGEMENT TEAM (MCM, PDC) • Monthly Product / PROVIDE STRATEGIC INTENT Project Committee Review Meeting. PROVIDE GUIDANCE • Management Committee DECISION MONITORING & Meeting MAKING CONTROL PROBLEM IMPLEMEN- ESCALATION TATION • Weekly Meeting PROBLEM RESOLUTION • Status Reports • Daily Meeting PROBLEM IDENTIFICATION THE PROJECT TEAM MEMBERS NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 20 [Company No.: 591026-M]
  21. 21. COMMON CAUSE OF FAILURES Supplier manpower not consistent 4 Insufficient measurable outputs 11 Supplier under resources 12 Supplier skills oversretched 13 Overall poor management 17 Mismanagement of progress 20 Costs getting out of hand 26 Inadequate coordination of resources 29 Milestone not being met 34 No quality Control 35 Lack of Planning of scheduling, resources and 39 activities Bad Communication between relevant parties 57 % 0 10 20 30 40 50 60 Source : The Bull Survey (IT Project) NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 21 [Company No.: 591026-M]
  22. 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. NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 22 [Company No.: 591026-M]
  23. 23. THANK YOU FOR YOUR ATTENTION NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 23 [Company No.: 591026-M]

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