Lean cost planning by Takashi Tanaka at the Lean IT Summit 2013
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The document discusses cost planning and reducing costs for new vehicle development. It begins with an agenda that includes explaining cost planning, managing cost planning through the development process, using systems engineering approaches, designing functions to reduce costs by 50%, and a Q&A session. Tables show costs of vehicles in developing markets and the cost structure breakdown. The document then discusses using functions to set cost reduction targets and scenarios, employing digital design reviews and simulations, and expectations that this approach can help reduce product costs by over 30% through changing work habits, global collaboration, and functional design techniques.
Lean cost planning by Takashi Tanaka at the Lean IT Summit 2013
- 1. 1 3DS_Document_2013 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012 Cost Planning Takashi Tanaka
- 2. 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
- 12. 12 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012
- 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 ｶﾞﾗｽ 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 ｻﾌﾟ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%
- 29. 29 3DS.COM © Dassault Systèmes | Confidential Information | 10/7/2013 | ref.: 3DS_Document_2012