2. Why don’t cars look like the beautiful car show
models?
Source: Toyota Europe (YouTube)
3. Historical Context
Mass Mass
Hand crafted
Produced customization
Image source: Toyota.com, Ford
4. …Modern variations can be in the millions
Variations offered on Ford Fusion:
Image source: MANAGING COMPLEXITY IN AUTOMOTIVE PRODUCTION
5. …and they must be made thousands of times per
month
Product Stanley HP DeskJet VW (new) Boeing 777
screwdriver Beetle
Annual 15,000 4 million 100,000 50
Production
volume
Sales lifetime 40 years 2 years 6 years 30 years
Sales price $6 $130 $20,000 $200 million
Parts 3 parts 200 parts 10,000 parts 130,000 parts
Team size 6 people 175 people 1,600 people 16,800 people
Development 1 year 1.5 years 3.5 years 4.5 years
time
Total cost $300,000 $75 million $900 million $6 billion
Source: Ulrich, Eppinger Product Design and Development
6. If you want one beautiful car, have a craftsman make
everything by hand
• http://youtu.be/La73Oy9ZGVw?t=2m8s
Source: CT Heritage
7. Ferrari makes more profit than Fiat does in revenue
(per vehicle)
Profit margin
Company Units Sold Rev (M Eur) Proft (M Eur)
(%)
Fiat 2,081,800 27,860 515 2%
Ferrari 6,573 1,919 302 16%
Per Vehicle:
Company Rev Profit
Fiat 13,383 247
Ferrari 291,952 45,946
Source: Fiat Group 2010 Annual Report
8. But if you want high quality at a fair price, design by
satisfying constraints quickly
Design
Sales Engineering
Production
10. Then prepare to build it thousands of times (mass
production)
youtube
11. Advanced version: do both simultaneously and iterate
(目的)
N-36 (month) N-24 (month) N-12 (month)
Engineering N
simultaneously
CE (CE構想)Development Styling - Design
Concept Proposal (開発提案) Approval (デザイン審査) - Production Engineering
▽ ▽ ▽ - Production (Plant)
Prototype Drawing (試作図面) - Supplier
Prototype Production (試作)
Vehicle SE
Development Prototype Evaluation (試作評価)
(車両開発) Regular Drawing (正式図)
Tooling & Equipment making
Production (型・設備製作)
Preparation
(生産準備)
Production Trial (号口試作)
Source: Toyota presentation 2004
12. An example of iterative flow in the Design Process
Paper Digital 3D Clay model
Design:
Sketches Drawings Rendering (full size)
3D
Engineering: CAD Doughboy
Drawings
Image source: Ford.com
13. When designers make the show car, they may not be
satisfying constraints for manufacturing and durability
Image source: Bloomberg
14. The ultimate goal is customer satisfaction (leads to
sustainable profits)
Image source: lexusenthusiast.com, carinsurance.org
20. … but live testing is required for confirmation
Image source: google image search
21. Previous evaluation ⑤ Re-try
① Put paint on inside of outer panel ② Set inner panel to outer panel
Repair → Re-design
③ Fitting confirmation ④ Modify part & re-design
by checking paint stuck porti on
Source: Toyota presentation 2004
22. Latest evaluation
+
-
Inner panel
- +
Outer panel
Digital Assembly
Interference
Source: Toyota presentation 2004
23. Buy a new car 6-12 months after a major/minor model
change
Major Major
6 years 6 years
Minor Minor
3 years 3 years
Annual Annual Annual Annual Annual Annual Annual Annual
1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year
• Minor problems sometimes cannot be addressed until the
next fix cycle
• Long-term testing takes time to complete
Camry life cycles (link)
25. Platform/Underbody is the heart of a car
• Like Windows 7
• Shared among vehices
• Defines major driving characteristics
• Engineering typically done at HQ
• See also:
http://en.wikipedia.org/wiki/List_of_Toyota_p
latforms
Camry platform (link)
29. Hand craftsmanship can have high variability
In January 1801 he went to Washington where
he made an unforgettable demonstration
before government officials. He spread out on
a table many parts of gunlocks, then randomly
picked up pieces to assemble a lock. He then
disassembled it and invited his astonished
observers to emulate him. In 1812 he was
awarded a contract to manufacture 15,000
muskets
Source: CT Heritage
Editor's Notes
Track test: http://youtu.be/3SYJjE7Xrf4
Ford Model T Roadster (represents an old crafted car; google searchFord 1913 plant: Ford assembly line, 1913. The magneto assembly line was the first. WikipediaTundra 2 cabs, 2 drives, 2 lengths, 3 engines = 24 types; toyota.com
Source: MANAGING COMPLEXITY IN AUTOMOTIVE PRODUCTION, H. Schleich, J. Schaffer, L. F. Scavarda, 19th International Conference on Production Research
Notes: Team size=Internal (peak) + external (peak), cost=development cost + production investmentSource: Ulrich, Eppinger: Product Design and Development
http://lexusenthusiast.com/http://www.carinsurance.org/2009 IQS results show Lexus at top
3:57 to 4:14
Mercedes SLS AMG 2009
See MTS documentLink to CamryStory=aichitoyota the lamp changed
Adding plastic grainSrouce: 6thgenaccord.com
Ferrari video: 1:10 create slolwy, limit production, wait 20 months; 2:15 1 tech 1 engine; 3:11 slow line…Kaikain: stamping, weld, paint, assy; 3:55 hand check qualityOntario: 0:51 to 4:49
Description Notes: This is a combination of several indices. Data from 1720 through 1747 are taken from Anne Bezanson, Wholesale prices in Philadelphia, A series of relative monthly prices. Philadelphia: University of Pennsylvania Press, 1936-1937 and 1954. From 1748 until 1912, the index of U.S. Commodity Prices collected by George F. Warren and Frank A. Pearson, Prices, New York: John Wiley & Sons, 1933, pp. 11-13 is used. This index used eleven groups of commodities including farm products (25-35 items), foods (25-27 items, hides and leather (4-5 items), textiles (8-10 items), fuel and lighting (.5 to 1), house furnishings (1), spirits (3-5), miscellaneous (1.5-3 items). The full index is available in CMWPCPIM. Beginning in 1913, the Bureau of Labor Statistics' all-commodity price index is used and is continued through 1947. For 1926 and later years the index was based on 784 commodities. See United States Department of Labor, Bureau of Labor Statistics mimeograph release No. 4313, January 1932. The current index has a base of 1982 = 100 and uses the All commodities Producer Commodity Price Index. The All-Industrial Producer Price Index, which begins in 1913, can be found in WPUSAICM. The Producer Price Index (PPI) is a family of indexes that measures the average change over time in selling prices received by domestic producers of goods and services. PPIs measure price change from the perspective of the seller. This contrasts with other measures, such as the Consumer Price Index (CPI), that measure price change from the purchaser's perspective. Sellers' and purchasers' prices may differ due to government subsidies, sales and excise taxes, and distribution costs. There are three main PPI publication structures: Industry-based. The PPI publishes over 500 industry price indexes in combination with over 10,000 specific product line and product category sub-indexes. Commodity-based. The PPI publishes over 3,200 commodity price indexes organized by type of product and end use. Stage-of-processing based. The PPI publishes aggregate price indexes organized by commodity-based processing stage. The three stages of processing include Finished Goods; Intermediate Materials, Supplies, and Components; and Crude Materials for Further Processing.Source: Federal Reserve Bank of St. Louis. The data is collected from the FRED database. The FRED database uses data from the Board of Governors of the Federal Reserve System, the Federal Reserve Bank of Philadelphia, the Federal Reserve Bank of St. Louis, the Office of Federal Housing Enterprise Oversight, The White House Council of Economic Advisors and Office of Management and Budget, the Congressional Budget Office, the U.S. Department of Commerce, the U.S. Department of Housing and Urban Development, the Bureau of Labor Statistics and the U.S. Department of the Treasury.