Seminar Presentation Design Excellence For Manufacturing Sustainability V1

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]

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.

Page 2

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
1986 2007 Page 3

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
[Company No.: 591026-M] Page 4

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


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


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

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

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


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

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

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


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

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)

Page 14

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

Page 15

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
Page 16

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


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

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%


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
Page 20

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)

Page 21

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.

Page 22

THANK YOU
FOR
YOUR ATTENTION

Page 23

Seminar Presentation Design Excellence For Manufacturing Sustainability V1

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