More Related Content Similar to Lean cost planning by Takashi Tanaka at the Lean IT Summit 2013 (20) More from Institut Lean France (20) Lean cost planning by Takashi Tanaka at the Lean IT Summit 20132. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Price for Developing Country
Indian Market Vehicle
Toyota
Etios ①
Nissan
Datson
Honda
BRIO ②
Suzuki
Alto
Hyundai
Eon
Ford
Figo
Tata
Nano ③
$ 8,300
Mobius
VW
$ 5,000
Tata
Nano
Bajaj
Datson unveil on 2014
Asahi News Paper, DIGITAL 2012, 5, 24
2
Logan
$ 2,000
2013, 3, 25 NIKKEI BUSINESS
RE60
3. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Agenda
3
1
Explanation of Cost Planning
2
To execute Cost Planning
3
Systems engineering
4
Functional design to reduce cost 50%
5
Q&A
4. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Cost Management
4
Development phase
(Month)
New automobile
development
-20
Planning
-10
Develop, Test
0
Prepare
Production
Design freeze
Accepting phase
Product
Cost
Cost
Planning
Cost reduction activity
Cost management
Cost sustaining
Cost improve
5. Cost Structure
Material
Example
Material
Metal sheet, paint, etc
Purchasing
Tire, audio, purchasing parts
Scrap, Defect
Material, defect parts, scrap
Production
Direct labor
Payment, bonus, etc
Depreciation, tax, insurance
Building, facility, tools
Indirect material
Tools, oil
Purchasing
Building, machine repair, maintenance
Other personnel expenses
Travel, transportation
Energy
In-direct
Labor & others
Total Product Cost/ Vehicle
3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Detail
Electric, air
Production engineering
Development
5
In-direct
Design, development, evaluation & test
6. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Target Setting
6
Sales Price
Target Cost
-3%
Cost
Purchasing & Suppliers
-30%
Cost Planning
Current
New
(Added more new
features)
7. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Bad Cost Reduction Activity
Added Cost
(New feature)
VE
Low possibility.
Unclear results
Heavy
Work-load
VE
VE
Cost reduction
activity
VE: Value Engineering
Current
7
VE
Rough
estimation
Target Cost
8. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Agenda
8
1
Explanation of Cost Planning
2
To manage Cost Planning
3
Systems engineering
4
Functional design to reduce cost 50%
5
Q&A
9. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Sample Project
Background
• Design in Japan and US, then production in China
• Product reduction target for 50%
• OEM expect suggestion to be a long-term partner
Development phase:
• Planning phase
• Using Oobeya for collaborative development
9
10. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Physical Oobeya: Basic Layout
10
Cost
Invest
11. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Goal of Digital Cost Planning
11
Reduce the time for DR: 5-days -> 2-hours
Reduction of development lead-time
Improve design quality
13. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Agenda
13
1
Explanation of Cost Planning
2
To manage Cost Planning
3
Systems engineering
4
Functional design to reduce cost 50%
5
Q&A
14. Systems Engineering
14
Entire
Vehicle
System decomposition
3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Development Process
Requirement
Test
Function
Total
System
Mecha.
Sub-System
Electric
S/W
Evaluation
Logical
SubSystem
Integrate
Test
Requirement
Function
Evaluate
Logical
Functional
Mock-up
Component
Digital
Integrate
Physical
Actual
15. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Digital Design Review
15
Digital mock-up
Functional mock-up
16. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Definition of RFLP
R
Market
Expectation
Electric
L
F
unction
Function
ogical
Structure
P
hysical
Component
• Device
• Measures
Mechanical
Software
16
equirement
User’s view
• Quantified
specification
• Parameter
• Definition of Input/
Output
• Detail design
• Plan & Circuit
• Architecture
• Schema
• Collaboration with S/W
• 3D Wiring
• Tubing
• Architecture
• Interface
• Source code
17. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Decomposition of Sun-roof
R
equirement
Cost
Weight
unction
Safety
Light
L
ogical
Frame
Internal parts
Sun light
Handling
Glass
Shut out
・
・
・
Temperature
・
・
・
hysical
External parts
Control light
Cool
P
Drive
NVH
Open/Close
・
・
・
17
F
18. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Agenda
18
1
Explanation of Cost Planning
2
To manage Cost Planning
3
Systems engineering
4
Functional design to reduce cost 50%
5
Q&A
19. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
By Function- Cost, make Cost Reduction scenario
Sun-roof
フレーム
Frame
Current
After
20
110
50
20
20
20
100
220
90
10
10
10
10
20
20
Shut out
10
10
10
Temperature
5
5
10
10
$45
$145
Total $400
Total $200
Function
動
Drive
Safety
80
ガラス
Glass
10
NVH
Open/ close
120
Sun light
Control light
Cost
10
$210
-50% Reduction
19
•Shocked about safety cost
• Change design concept
• Simulation effectively
•Competitor is only $90,
Bench marking
• Completely new design
20. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Opportunity to Improve
20
Over expectation of Drivability and Quality:
Change design concept completely
Barrier of KEIRETSU:
New and open relationship with suppliers
21. Scenario of Demo
3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
1.Using a carried over
RFLP of Sun-roof
Function- cost
decomposition
But +20Kg by
using big
vehicle’s
Overturned by
simulation
Reduced 50%
cost
Only +5Kg
No problem by
simulation
2.New design
Function- cost
Consider differently
Design change
Confirm design of
sun-roof
21
Reduced 50%
cost
22. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Cost Reduction Target: Break down
Input in CAD
R
equirement
R1
Common
F
unction
F1
F2
Trade-off
22
ogical
L1
L2
R2
R3
L
L3
P
hysical
P1
P2
23. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Cost Reduction -50%
1.Reduced cost using a carried over of sun-roof
23
24. Simulation
3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
1.Reduced cost using a carried over of sun-roof
Rem: Follow up later items is establish another file, GM checks w eekly.
Engine
Related
Face
Final
Order
Design Check Sheet
Eng Type
Factory Car Type
Distribute Other
Route: Design room -> Manager ->each CE
2- copy for group
Parts#
Name
Other
G
Depart
R
Outside design request #:
Design change #:
Requested section
Document, Memo
Cost
CE agree
Weight
GM
Leader
Establish
Order Final
M
Planning
Estimated
M
D
min
M
D
min
M
D
min Inspect drawing
Y-N
Y-N
Y-N
Final audit of draw ing
1. No problem
Cost Planning
Change drawing
$
(+ -
Outside design
Recognized draw
g
Outside
%) (
) (+ -
%)
Background, Objective
Others
Count
Research
Check VA, VE
with leader
2. No confirmation, but no problem
3. There is issue, but go
What is issue?
Change spec Commonalization
Reduce weight
Durability, Reliability check
Item
D
Purchase, Fin
Drawing
Performance Productivity
Solution of Issue
Service efficiency
Others
If it needed,
distribute to
production
engineering
of each factory
Continue hi-speed
Full throttle U/D
Low sw eep U/D
Total pattern
Total temperature
Low temperature
Ex main temp.
Long drive
Hammering
Stresses
Resonance
Dirt course
Hi-speed reliability
Heat test
Body test
CAE Stress
Explain:
Contents of change, Problems by GM
Attachment Planning figure
Engineering check sheet
Required specification
Objective, reason by GM
Performance Solution of Issue
NV improve
contact issue Others (
Request from others (CE, Production)
Commonalization
Service efficiency
Cost reduction SOC problem Others(
)
)
Reduce weight
Cost
Contents of change
1.SOP phase
2.Target cost
3.Current
4.Supplier estimate
5.Gap
Anxious by change
Countermeasure
Reflect for test (Left table)
Reflect to production
6.Countermeasure
Prototype
1.Parts cost
2.Mold
3.Total
Weight
1.SOP phase
2.Target cost
3.Current
4.Supplier estimate
If necessary
internally,
Copy
N
5.Gap
Later Recognized draw ing
OR Follow up ( Y - N )
Check grade
Plan ( /
)
Plan ( /
M
D
M
Item
D
)
6.Countermeasure
M
Check
D
M
D
Item
Check
Engineer 1
2GY 1
No issue
:
++
Regulation check require ( Y - N)
Conf irm with Material dep: rubber, plastic, paint
No guessing issue : +
Acceptance f or F/R, F/F
General name of material( )
Guessing issue : -
Parts list of OBD(On-board diagnosis)
Assembly and serv ice(Line tools, serv ice manual)
No countermeasure: -Not accept:
Saf ety issue (FH, Crash, OR, Leak)
Blank Conf irmation Engineering check sheet
Row material, process with prod. Eng & supplier
Conf irm guideline of parts f itting (Internal E2-14)
Including all PPC items
Drawing: parts table, request, label
The case of - and --,
Satisf ied required f unctions by reliability matrix
Change Drawing: old parts, ov ersea,
Write f ollow up date
Keep dev elopment target by justif ication check sheet
Parts table: Saf ety , regulation, maker option
Conf irmed by control design inf ormation matrix
Pattent:requested (Y N), Fall f ault (Y N Analy )
Implement DRBFM
Deliv ery location, change(
Prohibited design change, conf irmed by real parts
Conf lict of parts, distance, slack, f astened, seal
)
Env ironmental condition & inf luence
Oil, water & gas temperature, f rozen, f uel, etc
Caulking, weld, press, insert choking
Information
Leader comments:
Roll out other model(Y N), Influence other organization(Y N), informed(Y N):
Total
24
(Revised '05 June)
#1: Each engine & using area has template
#2: Attach engineering check sheet
Check sub-design check sheet of back side
25. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Design Change
2.Change design concept completely, using a new design and reduced cost
L
Safety
80
Frame
Total
10
20
110
20
100
220
NVH
Open/Close
120
Sun light
10
Control Light
10
10
Tempere.
5
$210
10
10 導風開口面積と最大高さh
Shut out
Total
25
Drive
Glass
20
F
$45
75cm2 :80mm
100cm2 :130mm
125cm2:150mm
20
10
5
10
$145
$400
26. Simulation after design change
3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
2.Change design concept completely, using a new design and reduced cost
サプライチェーンの見直しによる原価低減20%
26
27. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Expecting Target
27
Quality
A bit higher price level
Target
Price
Accomplish quality target
-Systems Engineering to reduce cost
-Using simulation effectively
-Quality into Process
28. 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
Summary
28
Cost Planning to reduce product cost of >30%
Change working behavior and habit
Global and collaborative activity
Functional design to reduce cost 50%