The Radical Engagement and Implementation of PDM in the

Manufacture of Automobile Parts

CHIE MATSUOKAMurase Electrical Corporation

Regular Manufacturing Industry Model

Japan/M.K.Japan/S.JPJapan/N.JPN AmericaThailand

ChinaCzech Rep.

Braziletc.

Product Cycle

U? ? ? ? ?

Res

ult

? ?

The Area of Automobile Parts Industries

ServiceSalesLogisticsMass ProductionDevelop Pre-

ProductionResearch

Sales

Preparation for Mass ProductionCost Planning

Preparation for Mass ProductionCost Planning CRMCRM

QCS(Quality/Cost/Speed/Expedite? CS

? Customer Satisfaction?

AccountingH.R. Mang.Production

Mang.SCM

Cost ½? α Time ? ? α

The Pressure of Innovation to Automobile Parts Manufacture

Business Supportby New Business System

The Improvementof Foundational

StrengthQ QualityC CostS Speed

The Improvementof Foundational

StrengthQ QualityC CostS Speed

Customer Requirement

Detail for Reform

Customer Requirement

Detail for Reform• Minimize cost to 1/2• Realize pre-production

period to 6 month• Globalize the

pre-production system

• Minimize cost to 1/2• Realize pre-production

period to 6 month• Globalize the

pre-production system

• Within the gymnasium environment

• Cost cycle system• Improvement

productivity

• Within the gymnasium environment

• Cost cycle system• Improvement

productivity

Needs for Internal Business

Innovation

Needs for Internal Business

Innovation

• Pre-production system

• Cost planning system

Critical Tasks for Immediate Action

The goal is to decrease time period, cost, bring the quality up in a gymnasium environment and while visualizing simultaneous engineering, accumulate the pre-production for knowing how by the work flow

22

33Management of cost planning and implementation with technical expertise results in making cost totally controlled

Decreased non-productive work by implementing PLM system for integrated management and sharing of information throughout design, prototyping and pre-production

11

Quality Control (QS9000)

Cost(Cost project?

Speed Up(Visualized workflow,

bring up pre-production?

Take care of your own Documents because there is

No work-flow

Take care of your own Documents because there is

No work-flow

Attachment 1Decreased of Non-Productive Work Time by Integrate

Management for Design, Prototyping and Pre-production

PresentPresent AfterAfter

EDMICSEDMICSTechnical

BOMTechnical

BOM

Mass Production

BOM

Mass Production

BOM

I have to deliver all documents by hand

Input data to host & savethe illustration to EDMICS,

however, delivery it by paper.

Oops!! Process Meeting, I might not make

it on time

All the Excel documents for other dep.

However, I have to manuallyenter into the sys.

(Delivery copy)

(Delivery copy)

(EXCEL Paoer) Ability to check the process

any time

Schedule DataSchedule Data

Punch Drawings?DR Document・・

Technical BOM

Technical BOM

PathWayPathWay

Mass Production

BOM

Mass Production

BOM DrawingDrawing

TechDocument

TechDocument

QualityData

QualityData

3D XVL3D XVL

Attachment 2To Promote SE Activities in an Imaging Gymnasium Environment and Knowing how

to Accumulate the Improvement

Solicitation Prototyping Order Regular Production SupplementEngineering

Change

SE Activities SE Activities

Technical Process Room

N. America

Brazil

Thailand

Czech Rep.

Indian

S. Africa

FranceChina

Indonesia

Japan

Mass Production

Mass Production

Mass Production

Mass Production

Mass Production

Mass Production

Mass Production

Mass Production

PreparationProduction

PreparationProduction

Set up Sales Price

Estimate Price Schedule

Process Plan for the Project

Achievement

1WPart・Equipment Qualification Success Rate

Accomplish it with expertise in the present location for cost supervision

Set up sales price /support of budget

assignmentTeam-work for the progress check regarding the

achievement for anticipated projected cost

EstimateCost

EstimateEstimateCostCost

ProcessPlanningProcessProcessPlanningPlanning

LiningTry

LiningLiningTryTry

RegularProduction

RegularRegularProductionProduction

Cost ManagementCost Managementfor revising unit pricefor revising unit price

Cost PlanningCost Planning

Following-Up Defects

Attachment 3Manage Cost thorough by Making Informational System

Cost Supervision ManagementCost Supervision Management

Case StudyTypical Example for “A” Corporation Pertaining to the Pre-

Production System

• Business process innovation to survive as Tier 1 supplier

• The internal pre-production system developedwith a goal to integrate all activities

• Included changing the business workflow,not just system implementation

• Let technological expertise pertaining to the entire system clarify the possibility of an actual intra-office (internal system) and make this an achievable goal for the cost project

• To achieve the preceding requirements, considers how SE activities to be in early stage (N-40)

Needs to Build Information Infrastructure that Enables Quality Highly, Cost Lowly in the Stage of Accepting Orders, Also Enables Preparation for Mass Production Time Shortly

Goal of “A” CorporationVisualizing the Entire Corporation SE Activities and Preparation for Production in a Gymnasium Room

Requirements for AcceptingOrders & Customers

Requirements for AcceptingOrders & Customers Agenda PlanAgenda Plan

Examining ProductivityExamining ProductivityLoad in Preparation for Mass ProductionLoad in Preparation for Mass Production

Cost GoalManagement

Cost GoalManagement

Do Not Repeat Past Mistakes

Do Not Repeat Past Mistakes

Check for Mass Production

Check for Mass Production

6.6.

7.7.

8.8.

4.4.

2.2.

5.5.

1.1.

How much for cost? How about actual availability of cost? Goal for sale price? Goal for cost?Present achievement status?

How much for cost? How about actual availability of cost? Goal for sale price? Goal for cost?Present achievement status?

Incorporation includes correction for past mistake, prior errors? Are we on the right track?

Incorporation includes correction for past mistake, prior errors? Are we on the right track?

Problem regarding assumption of production line? Is this going to work out?

Problem regarding assumption of production line? Is this going to work out?

Sales activity・Customer Requirement.・Customer information? Capability guarantee and determine evaluation method?

Sales activity・Customer Requirement.・Customer information? Capability guarantee and determine evaluation method?

How to make agenda for pre-prod. Develop.?How to move forward? Is it going be late?

How to make agenda for pre-prod. Develop.?How to move forward? Is it going be late?

What abut the quality of goods?Is it accepted? Problem for production method? Need new method required ?

What abut the quality of goods?Is it accepted? Problem for production method? Need new method required ?

What is the situation for pre-production load?What about load for equipment type manufacturer? How about outsource load?

What is the situation for pre-production load?What about load for equipment type manufacturer? How about outsource load?

Internal Condition Internal Condition 3.3.Where is Production Point?Where is the Line (Load check)?Use existing Line or buy new one?Enough space?

Where is Production Point?Where is the Line (Load check)?Use existing Line or buy new one?Enough space?

Goal of “A” Corporation : Visualizing The Entire Corporation SE Activities and Preparation for Pre-Production in a Gymnasium Room

　　

Accepting Orders Strategy, Solicitation Infor, Development Plan, Customer Schedule

A Technological Estimate VS Customer RequirementRivalry other company estimate

Estimation of line operation rate & the value of simulation

Profit simulation for order time Predication of Investment(R&D, Equipment)Technology and Pre-production man-hour

Pre-Production PhaseTask Management

Tasks for Acceptiong OrdersReason, Counter Measure,

Action, Result

An Initial Plan Development Acc. Orders

Pre-Production SOP MassProduction

Visualization of Accepting Orders and Tasks

Internal Requirement for Accepting Orders (Items to be considered)

Visualization for acceptiong

orders’condition,

tasks and roles

Concept / Prototype DWGs, Customer Information

Judge Information

Accept/N

ot Accept

SE Examination, Cost Information

Predication for manufacture operation

Acc. Orders

Key:Car model, Order list

Sales

Tech

PE Cost Mgmt Information

Daily Process Information

Technical Information Product

Mgmt

PE

Feedback of Improvement

Pre-Production, Regular Order, SOPSale InformationSet up

Process With

Goal of AgendaAnd

Goal of Cost An

Absolute Reality

Mass p

rod

uctio

n co

st, pro

fit rate, the

equ

ipm

ent o

f op

eration

rate

Evalu

ation

man

agem

ent d

urin

g th

e p

roject L/O

HVPT

The activities achievement for

goal

Development Progress Informaiton

Accepting Orders, Solicitation Information

Key : Car model, Order Number

BOMBOM

SOPSOPStartStart

Cost Planning/Technology Estimating• BOM• Estimate cost for every unit ? requirement for estimating

• AS BOM? approval figure?• Issue guidance illustration• Prototype BOM

• Issue new arrangement book• BOM for customer, EC• Delivery schedule direction, change

Customer name, List,

SOP?delivery

schedule?delivery

location?set up times

Preparation for mass production scheduleBOM

Preparation for mass production scheduleBOM

BOM Arrangement

Preparation for mass Production Schedule• Preparation for mass production schedule, include changing/outcome• Internal ? source

• Path way BOM• EC after mass production

Development - Pro-production Estimate

• Bill of Material• Arrangement, Manufacturing,

Purchase, man-hour outcome

Prototyping

• Decision in-house/outsource• Purchase vendor decision

• Starting sales activities• Circumstances of estimation• Internal cost retention• Prototyping order

Process of Accepting OrdersCustomer Schedule

& Order Policy Up to 5 Years

RequestEstimate Request

Estimate

• Checking approved drawings out• First expected prototyping date• SOP

ProjectDevelopment

• Start development

• DR formal illustration?• Capability confirmation DR?

Customer master schedule?outsource equipment application resolution day

SOP others are assumed

Customer master schedule?outsource equipment application resolution day

SOP others are assumed

Mass Prod.Cost

Mang.

Mass Prod.Cost

Mang.

• Management for achieving benchmark

Cost Supervision

Regular Purchase• Type? equipment, supplemental tool• Restricted material, supplement

• Actual order of parts• Order priority materials

“A” Corporation General Business of Preparation for Mass Production

VS Business of Cost Planning

eMatrixeMatrix

System Requirements for the Individual Corporation “B”

Typical Pre-Production System Example for Corporation “B”

• Examine the process of general business system development

• Include outside sources and correct promotions that will be focused on the main function of business development

• By suitable design technological capabilities, the investment VSoutcome does not match

• Improve the productivity for those who are concerned with pre-production resulting in (reduce time for searching documents、progress conditions grasping, reduce time for meeting and communication）

• Making a development stage for managing the system of the cost business project and make the possibility for progress withcost supervision condition

• Making possible wok flow structure which will be linked to overseas pre-production issues

Mass P

rod

uctio

n

Mo

ving

Pa

th

３次元CADData Management

３次元CADData Management

Sales/Estimate Cost System

Pre-Prod. Plan Sys.

Project Lift Cycle System ? PLM)

Supplier Sample System

Support CostEstimate

Support CostEstimate

Pre-ProductNO Management

Pre-ProductNO Management

Pre-Management for Guidance Develop

Pre-Management for Guidance Develop

Pre-Production Schedule Manage.Schedule

Pre-Production Schedule Manage.Schedule

Order ManagementOrder Management

Receive/CheckReceive/Check

Recycle ManagementRecycle Management

Supplier Process Management

Supplier Process Management

Overseas Supplier Management

Overseas Supplier Management

Metal Pattern LedgerMetal Pattern Ledger

Check ReceivableCheck Receivable

Internal Process Opportunity System

Pre-Estimating forPattern ManagementPre-Estimating for

Pattern Management

Pipe PatternAnalyze Management

Pipe PatternAnalyze Management

Pattern Renew Management

Pattern Renew Management

Pattern ConnectingManagement

Pattern ConnectingManagement

Internal Outcome/Man-Hour

Internal Outcome/Man-Hour

Pre-Sale Price Support.Pre-Sale Price Support.

Set Up Cost ScheduleSet Up Cost Schedule

Estimate Cost Mgmt.Estimate Cost Mgmt.

Cost -TableCost -Table

Process/Processing Condition

Process/Processing Condition

Step 1Step 1

Step 2Step 2

Step 3Step 3

Pre-ProductionDatabaseeMatrix

PrePre--ProductionProductionDatabaseDatabaseeMatrixeMatrix

Renew Pre-Product Specification/Renew Guidance?Order (Workflow~Info. Management.)

Renew Pre-Product Specification/Renew Guidance?Order (Workflow~Info. Management.)

Production Requesting/Information Delivery

Production Requesting/Information Delivery

Quality/Rearing InformationManagement

Quality/Rearing InformationManagement

Dead Line ManagementDead Line Management

BOM ConnectionBOM Connection

２次元Draw Management(TIF Illustration)

２次元Draw Management(TIF Illustration)

Managing Document (word excel etc.)

Managing Document (word excel etc.)

Set up Process Value/OutcomeSet up Process Value/Outcome

Vendor Unit Price? Material・Processing・Surface, etc.)

Vendor Unit Price? Material・Processing・Surface, etc.)

Delivery/Packing・Other expenseDelivery/Packing・Other expense

Cost Supervision Management System

The Extra Requirement forChange Elements

The Extra Requirement forChange Elements

Bill of Material Management(EBOM)

Bill of Material Management(EBOM)

V-Concept of Buy/Sale System

Supplier Management System

The Entire Pre-production System Illustration for Corporation “B”

Step 4Step 4

Order ManagementOrder ManagementInternal ProcessSpecification Management

Internal ProcessSpecification Management

Manufacture SpecificationManufacture SpecificationSupplier DocumentSupplier Document

Progress ManagementProgress Management

Display for ProcessDisplay for Process

Display ProcessDisplay Process

Inventory ManagementInventory Management

Receivables OutcomeReceivables Outcome

Analyze for IndividualProcess Management

Analyze for IndividualProcess Management

Total Cost ManagementTotal Cost

Management

Processing OutcomeProcessing Outcome

Cost Project System AreaCost Project System Area

Business Image for “B” Corporation Pertaining to the Pre-Production System during Operating Time

Pre-production System AreaPre-production System Area

Renew/Change Register

Cost Planning

DB

Bill of Material

BOM

Inquiry of BOM

Pre-productionSpecification

Process Plan

XVL

Business Image for “B” Corporation pertaining to Pre-Production System during Operating Time

BOM (Matrix)

ScheduleManagementDB (Matrix)

Schedule Register for Metal Pattern/Tool

Supplier Will Access by InternetInput Plan/Input Outcome

WEB Site forPublic User

Internet

Automobile Type/Part Number Gantt Chart

・Solicitation・Order・Input plan・Input audit

Pre-Production Schedule Management System

Phase 1 (Internal pre-product progress management)? ? Anticipated Outcome

Reducing the process time for searching illustrations, storage and distribution.Reducing the time for keeping files, preparation, and distributionReduce the time for researching and distributing the information for new pre-productionReduce the time of notification and judgment for illustration changes Exclusion of management man-hours for the pre-production progressReduce the meeting time regarding pre-production

Phase 2 (The assessment of specifications for suppliers, and pre-production that connects to manufacture)

? ? Anticipated OutcomeReduce the work time of keeping files for suppliers, create documents and distribute (deliver)Reduce the meeting and communication time with suppliers/manufacturers (maker)Reduce the work time for equipment management progress for material such as metalReduce search time, work for management of support manufacture documents suchas pattern figure, report of attempts, VB, proposal of VA, methods for unsuitable items and so on Reduce work time for inquire pertaining to progress of sales and technology

Phase 3 (Cost project, estimate for sale price, cost of table for buying, and value for sample cost product adjustment)

? ? Anticipated Outcome? Reduce work time for making cost list (layout)

Value of cost project to have 100% match estimate sale priceGoal of cost progress management for cost rearing (supervision) periodReduce the inquiry search time or the implementation of entire department management for cost informationReduce the job for cost revision to customer correspondence

Phase 4 (Connection to internal opportunity, assist the manufacture with others)? ? ? ? From now on, we will be a premise system business model

Development of Year 2004

Development Development of Year 2004of Year 2004

Expected Results for the Pre-Production System in “B” Corporation

原価 (Cost)• It is necessary to prepare and build team-work for cost project• Collusion for management result of various changes

regarding the actual cost• Cost will be made by different stages of development and flow

teamwork will be controlling the supervision of cost (cost preparation)

全社統合 (Global Integration)• It is difficult to unify the entire team-work

process at the present location• Clarifier the area for integration (unification)

現場最適 (Optimum Present Location)• Create other values in manufacture industry • First priority is to support the supplier

eMatrix

A View Point to Build NPID from Now On

Is it going to be early?

Is it going to be less expensive?

Is it going to be soon?

Business model in the manufacture industry

安? Economical

近? Quick

早? Early

Is it going to be early?

Is it going to be less expensive?

Is it going to be soon?

Business model in the manufacture industry

安? Economical

近? Quick

早? Early

Thank You!