Lightweighting , Vehicle,
- 1. Advanced Lightweight Materials Summit Topic Weighing the costs of Light Weight Material Implementation Thomas Turner Nicholas Nickson Ashley Turner 8/28/2012
- 2. Author’s Comment My policy is to grow my clients Bottom Line by educating their people and improving their processes.
- 3. Truths we should hold to be self- evident •It takes 10,000 working hours in a given trade to become competent. •Warranty Costs combined for Supplier and OEMs are 10-15 Billion Yearly. •Warranty costs are split between Suppliers and OEMs fairly evenly. •By 2016 Café Standards will have driven us all to extremes in vehicle lightweighting. •Lightweighting of vehicles encompasses all the raw materials used to make the vehicle/components. •Experience of those needing to do lightweighting of vehicles requires extensive knowledge of manufacturing and materials.
- 4. What we are going to do today? •Discuss problems we find in the current Engineering/Manufacturing models. •Define where we want to be in the future. •Define a generic mass reduction model
- 5. Problems in the USA Manufacturing/Engineering models.
- 6. Problems in the USA Manufacturing/Engineering model. Lets start with what we know •Product Knowledge resides in the Supply base but critical guidance of usage lives within the OEMs.. •Between 2008 and 2012 a terrific experience loss occurred due to the economic downturn. •We know that our industries have trouble with reoccurring mistakes. •We know that Cost and Weight reduction efforts sometimes stall and provide poor results. •We know that with the introduction of new technology, a great deal of our Engineering efforts are becoming more computerized. As a result our Engineers are doing more Program Management. Both Suppliers and OEMS agree that manpower is the biggest issue in Lightweighting , Lowering Cost, and Improving Quality. I believe it’s also quality and use of those people.
- 7. Problems in the USA Manufacturing/Engineering model. What can we fix that would affect what we know? •Separation of Engineering and Manufacturing needs to be re-thought. •Bundling of efforts is the key to success in paying for and realizing weight reduction, cost reduction, and quality improvements. •Leadership needs to be granted based on experience and team building.
- 8. Problems in the USA Manufacturing/Engineering model. What can we fix that would affect what we know? •Separation of Engineering and Manufacturing not such a good idea. Current product lifecycle model – Advanced Engineering - Product Engineering – Manufacturing develops process for manufacture - Launch Proposed- Blended Manufacturing and Engineering develop product while developing process – launch Major Change- 30% of Engineering staff needs to be populated with Manufacturing specialists.
- 9. Problems in the USA Manufacturing/Engineering model. Current Model “worst case” The Truth Engineer Engineer Engineer Supervisor Manager 3,000 hrs experience 5,000 hrs 10,000 hrs Significant savings in weight experience experience Product A Product A Product A are being achieved through the use of multiple material combinations. However, we Proposed Model “worst case” can not expect novices to think Engineer Engineer outside the box and succeed Engineer 10,000 hrs Supervisor Manager when average success is a 15,000 hrs 20,000 hrs experience experience experience struggle . Product A Product A Product A
- 10. Problems in the USA Manufacturing/Engineering model. I find team building to be lacking in most of our medium to large corporations. I have had great success in helping teams to grow with a few simple rules: 1. As the leader I will enthusiastically take the blame for all things done wrong by the group. 2. Praise loud and often . 3. Use humor to relieve social pressure. 4. Care for the success of all under you. 5. Explain what you want from your people and give examples so when they know when they are doing right and when they are doing wrong. 6. Make fun of yourself. Self depreciative humor connects people through vulnerability. 7. Willingly work for your employee as a subordinate when they need help. i.e. jump in and crunch numbers or carry parts for them.
- 11. Problems in the USA Manufacturing/Engineering model. Bundling: Why bet it all on one card?
- 13. Weight Reduction model 1. Establish the rules 2. Gather data 3. Gather the team 4. Associate data with Specialists 5. Target areas of opportunity 6. Make the changes 7. Validate
- 14. Establish the Rules The goal is to have the Weight Reduction effort provide a more effective, lighter vehicle at lower cost. The contract agreed to by all the participants is key for defining success. This contract will incorporate the following: • Length of cycle. • Set up repeat effort with lessons learned. • Use of projected savings to offset current expenses. • Understanding that validation of what we have currently is a success also. • Final decision process for implementation (Bullet proof)
- 15. Establish the Rules Part 2. Bundle for success – •Reduce Carbon Footprint •Reduce Raw Material usage •Increase throughput •Lower Material Costs •Increase product life •Lower Running Costs •Simplify Assembly •Prepare for secondary efforts •Explore and use tax advantages
- 16. Gather the data Information: • Warranty/Repair history • Understand raw material utilization • Categorize components by manufacturing process • Group Common products for bundling • Review cost and process at suppliers • Conduct Transportation evaluation • Define safety items • Define injuries and vehicle failures in use • Review supplier weight and cost reduction ideas • Interview users • Comparative analysis with other vehicles • Software update process, cycle, and cost How you incorporate this information will greatly affect speed and success of this effort.
- 17. Gather the team The team should be biased based on the content of the vehicle and cost content. Minimum requirements: Welder Fabricator Casting Specialist Plastics Specialist Machinist Estimator Electrical Specialist Software Specialist Buyer Ceramics specialist
- 18. Associate data with Specialist teams Welder Fabricator Casting Specialist Plastics Specialist Machinist Estimator Electrical Specialist Software Specialist Buyer Flat sheet and formed metallic parts -Analyze Repair and Warranty costs for cost reduction and functional improvement. -Validate Best Practice for the manufacture and joining of the parts. -Alternatives for improvement and cost reduction brain storming. -Compare estimated cost with real cost. -Financial evaluation of bundling components and shipping
- 19. The Success of these teams is greatly dependent on how the teams are scheduled and lead. Daily – Review of previous days progress Identify road blocks List opportunities and days schedule Break into teams Weekly group discussion- Review whole vehicle Use Safety items Vehicle requirements Brain Storm Review each other’s team progress Set goals for the week
- 20. Questions?
Editor's Notes
- #2: This template can be used as a starter file for presenting training materials in a group setting. Sections Right-click on a slide to add sections. Sections can help to organize your slides or facilitate collaboration between multiple authors. Notes Use the Notes section for delivery notes or to provide additional details for the audience. View these notes in Presentation View during your presentation. Keep in mind the font size (important for accessibility, visibility, videotaping, and online production) Coordinated colors Pay particular attention to the graphs, charts, and text boxes. Consider that attendees will print in black and white or grayscale. Run a test print to make sure your colors work when printed in pure black and white and grayscale. Graphics, tables, and graphs Keep it simple: If possible, use consistent, non-distracting styles and colors. Label all graphs and tables.
- #13: This is another option for an Overview slides using transitions.
- #21: Microsoft Engineering Excellence Microsoft Confidential