Design Excellence

Kamarulzaman Darus PJN Director of Manufacturing NAM kzamandarus@nam.com.my +6012-277-2059 Graduated in B.Sc. Mechanical Engineering from 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. Design Excellence for Manufacturing Sustainability NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 1 MALAYSIA’S INDUSTRIALIZATION MASTER PLAN Industrial Master Plan (IMP) 1986 - 1995 Industrial Master Plan 2 (IMP2) 1996 - 2005 • • • • • • Moving beyond manufacturing operations to include : Indigenous R&D and technology Design Capabilities Integrated supporting industries International marketing Development of own Brand World class, world scale Three broad objectives: • Ensure rapid expansion of the economy through acceleration of manufacturing sector growth • Promote efficient and optimum utilization of natural resources through value-added manufacturing activities • Lay foundation for the 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. NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 2 INDUSTRY CAPABILITIES TRANSFORMATION MANUFACTURING DESIGN & ENGINEERING VIRTUAL PRODUCT VPDM DESIGN & MANUFACTURING MILEAGE ACCUMULATION MACD CHASSIS DYNAMOMETER Climatic Chamber, Engine Test Cells) CMSS (4-Poster, Kinematics Rig, (4Crash Sled, Components Tests Laboratory) PROTOTYPING - Rapid Prototyping (SLA, LOM) , Prototyping Centre CADDS (Computer-Aided Design System) CAD (EUCLID, (ComputerCATIA ® ), CAE, CAM Local Vendors Development Note: Major Tests and Validations would still be Conducted in Tests Centers such as at Millbrook, Idiada, Crashlab etc. STYLING, MODELING & ERGONOMICS SHTT (Semi-High Speed Test Track), Emission and (SemiNoise 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 NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] 2007 Page 3 INDUSTRY DIFFERENTIATORS •Platform Engineering •Modular Engineering •Short Lead Time from Ordering to Delivery • Product Life Cycle halved • SE/CE Teams • CAS/CAD/CAE; VR Product Variety Product Variety Marketing Marketing Reduced Reduced Product 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 Lower Volume Wider Range Wider Range • Flexible Manufacturing System (FMS) ““Real-Time” Real-Time” Logistics Logistics •EDI, JIT •Configurable BOM Automation Automation CAD / CAM / CIM KEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAIN KEY: DESIGN STRATEGY: KNOW-HOW & TOOLS DEPLOYMENT INTO THE VALUE CHAIN NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 4 VALUE CHAIN TOOLING: STAMPING DIES, PLASTIC MOULDS DESIGN & DEVELOPMENT COMMON PLATFORM PLATFORM ENGINEERING TESTING & VALIDATIONS STAMPING STYLING DESIGN PRODUCT ENGINEERING BODY WELDING AND ASSEMBLY INTEGRATED AND DIFFERENTIATED BY PAINTING TECHNOLOGY (DESIGN & ENGINEERING) FINAL ASSEMBLY LOGISTICS & DISTRIBUTION PRODUCT VENDORS COMPONENT DEVELOPMENT and SUPPLY & EQUIPMENT SUPPLIERS MARKET (SALES & MARKETING) POWERTRAIN DESIGN & MANUFACTURING NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 5 INDUSTRY LEVEL OF CAPABILITIES SUSTAINABLE MANUFACTURER ….. ECONOMIES OF SCALE ~ MINIMUM 30K/MODEL/ YEAR CONSUMER GLOBAL MARKET BRANDING QUALITY PRODUCT QUALITY COMPONENT •Competitive •Global Source Loyal •Strong Brand •Delighted Consolidated •Global & Regional Network •“Own” Car •“Own” Brand •Low Cost •Desirable •Up-to-Date Up- toCOMPLETE SUITE OF DESIGN TOOLS & FACILITIES (INCLUDING VR) PRODUCTION SYSTEM •“Flexible” •‘0’ Defect •‘0’ Stock •Knowledgeable •Up-to-date Up- toInformation ORGANISAORGANISATION MAKE TO CUSTOMERS’ CONFIGURED ORDERS GLOBAL MARKETING FULL RANGE MODEL DESIGN VENDOR PARTNERSHIP (1st TIERING) FLEXIBLE PRODUCTION SCHEDULING ADVANCED MANAGEMENT •Empowerment •Teams MAKE TO ORDER GLOBAL PRESENCE •Selected Markets •Strong in ASEAN MULTI PLANT OPERATIONS •Own •Contract •CKD ‘IN-HOUSE’ INDESIGN DEEP DESIGN COMPETENCE INTEGRATED SUPPLY CHAIN SOUND MATERIAL PROCESS FLOW •JIT, CC •KANBAN GOOD PRODUCTION SYSTEM •Process design TIMELY, ACCURATE, AND INTEGRATED INFORMATION SOUND PROCESS and CONTROL •Financial •HR ASSEMBLE TO DISTRIBUTORS’ ORDERS BASIC MODIFICATION DESIGN CROSS FUNCTIONAL DESIGN TEAMS MATERIAL COST MANAGEMENT ASSEMBLE TO STOCK DOMESTIC DOMINANCE PARTNER DESIGN BASIC DESIGN TOOLS AND FACILITIES VENDOR DEVELOPMENT SIMPLE PRODUCTION SYSTEM BASIC FUNDAMENTAL NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 6 CAPABILITY DEVELOPMENT Value Chain High Technology High Knowledge Application P e siv es gr ro IP High Employment 1:10 = 100,000 gr Re iv ss e e IA D (IN F US RIA T J AD L EN M US FU T N S) D OWN PRODUCT DESIGN RnD CENTRE & ENGINE MFG 1:6 = 40,000 PLATFORM MFG High Labor Assemble Localize 60% CKD R&D Centre, Product Design, Powertrain & Tooling Manufacturing . 1:1 = 600 25 years NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 7 PRODUCT DEVELOPMENT ELEMENTS EFFECTIVE INITIATIVES BOARD Project Management Process Engineering DESIRED DELIVERABLES MARKET Cost Vehicle Simultaneous Design, Engineering Engineering & Development Engineering Simulation & Analysis Plant Set-Up Weight Design Machinery, Equipment & Facilities Quality Performance Delivery MANAGEMENT TOTALLY INTEGRATED IMPLEMENTATION NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] PRODUCTS Page 8 ADVANCED VIRTUAL ENGINEERING Design Style Presentation Structural Performance Safety Control Dynamic Performance Assembly Possibility Formability Possibility Quality Control DU RE G IN C PM O EL V Virtual DE TIM NT E G IN & ST CO 3D CAD Modeling Reality Durability Analysis Crash Simulation Vehicle Dynamics Analysis Digital Mock Up Metal Forming Analysis Tolerance Analysis NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 9 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 No of design change CAE Mule vehicle Alias styling Verification model Formability DMU The historic More cost for design change and market warranty Planning Styling Proto Pilot S.O.P Prod. NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 10 COST CONTROL & BENCHMARKING PAST Design Design Present Estimated Estimated sales price sales price Target cost Target cost set up set up DTC Design To target Cost Parts develop. Parts develop. Purchasing Purchasing Manufacturing Manufacturing Cost totaling Cost totaling BTC Buy To design Cost Sales price Sales price Cost reduction by design change - Investment - Lead time Loss [Company No.: 591026-M] SE, GE of parts development, purchasing, manufacturing, vendors NAZA AUTOMOTIVE MANUFACTURING SDN BHD Page 11 DESIGN VALIDATION Concept Verification Vehicle Initial Tuning - Hard Points - Specification & etc. Abuse Test Structural Durability Test Proto Spec. set-up Product Validation Install & Instruction Quality Control Productivity Design Library Benchmarking Concept study Initial Design Component & Pretest Develop Prototype Develop Production Preparation Concept Develop Target Study Lay-out & Package Dynamic Simulation Performance Analysis FEM Analysis LS-Dyna Abaqus Pam-Crash Auto Form Mark II Nastran ADAMS Design Verification Vehicle Fine Tuning Production Spec. set-up Durability Test Cost & Weight Control NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 12 PRODUCT DEVELOPMENT SYSTEM – Computer-Aided Automotive Development (CADDS) PRODUCT PLANNING Package Layout Drawing Ergonomic Study Concept Design Sketching & Rendering STYLING 3D Modeling Animation & Design Presentation PROTOTYPE Digital Mock-up DMU 1:1 Clay 1:1 BIW Computer Aided Ergonomic Study CATIA / Safeworks Parts Digitising & Modeling Reverse Engineering Computer Aided Industrial Design ALIAS Paint; Auto Studio; Eclipse Composer CATIA - Class ‘A’ Surfacing Rapid Prototyping Maestro - SLA/LOM - SliceLOM -Magic RP 5-Axis Milling Machine, Digitising Product Analysis & Learning Suppliers / VendorVendorModules/Systems Powertrain CATIA Engineering Design Layout Drawing Parts Design Drawing Assembly Design Harness Design & Layout Interference Checking Homologation & Testing NVH Component Material Endurance Performance Emission Crash REDESIGN Robot Programming Computer-aided Design Computer- * R&H CATIA Structural Analysis (Linear) Crash-worthiness & Occupant Safety NVH Computational Fluid Dynamics Electrical Electronics & EM Analysis Emission, Performance & Safety Anaechoic Chamber, Strength & Material Laboratories, Sled Test Rig SHSTT (Test Track), Simulation Road Surface Track 4-Poster Driving Simulation Rig, Kinematics Rig, Engine Dynamometer Computer Aided Engineering and Virtual Testing MSC-PATRAN MSC-NASTRAN ADAMS Manufacturing LS-DYNA 3D Process Planning Dies Design Stamping Simulation NC Tape Generation Assembly Jig Inspection Jig Robot Simulation Assembly Line Simulation Computer Aided Manufacturing Computer Aided Assembly/Robotic Simulation AUTOCAD, CAD/CAM-CATIA/CADAM NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] ROBCAD, WITNESS Page 13 PRODUCT DEVELOPMENT SYSTEM – NPI Integrating Activities Model PEOPLE PEOPLE “SOFT” NPI “SOFT” NPI ACTIVITIES ACTIVITIES PROCESS PROCESS NEW PRODUCT NEW PRODUCT DEVELOPMENT DEVELOPMENT STRATEGY STRATEGY TOOLS & TOOLS & TECHNIQUES TECHNIQUES “HARD” NPI “HARD” NPI ACTIVITIES ACTIVITIES FORMAL FORMAL METHODS METHODS [Company No.: 591026-M] • • Cross Functional Teams Cross Functional Teams • • Team Leadership Team Leadership • • Team Development (Education & Team Development (Education & Training) Training) • • Reward and Recognition Systems Reward and Recognition Systems • • Co-Location Co-Location • • • • • • • • • • Project Management Project Management Formal NPI Procedures Formal NPI Procedures Customer-Supplier Integration Customer-Supplier Integration Formal Team Briefings Formal Team Briefings Organization Re-Design Organization Re-Design Computer/Networks (Common Computer/Networks (Common Database) Database) • Computer-Aided Design (CAD) • Computer-Aided Design (CAD) • Computer-Aided Engineering (CAE) • Computer-Aided Engineering (CAE) • Computer-Aided Simulation (CAS) • Computer-Aided Simulation (CAS) • • • Quality Function Deployment (QFD) • Quality Function Deployment (QFD) • Design of Experiments (Taguchi) • Design of Experiments (Taguchi) • Design for Manufacturing / Assembly • Design for Manufacturing / Assembly (DFM/DFA) (DFM/DFA) • Failure Mode & Effect Analysis (FMEA) • Failure Mode & Effect Analysis (FMEA) Page 14 NAZA AUTOMOTIVE MANUFACTURING SDN BHD PRODUCT DEVELOPMENT SYSTEM – NPI Process 11-STEP PROCESS 11-STEP PROCESS 1 1 INITIAL SCREENING INITIAL SCREENING KICK-OFF KICKKICK-OFF PROJECT INITIATION PROJECT INITIATION PROJECT DIRECTION PROJECT DIRECTION PROJECT (MODEL) FIX PROJECT (MODEL) FIX PROJECT APPROVAL PROJECT APPROVAL PROJECT DESIGN PROJECT DESIGN APPROVAL APPROVAL PROJECT FINAL PROJECT FINAL APPROVAL APPROVAL PRE-PRODUCTION PREPRE-PRODUCTION APPROVAL APPROVAL PRODUCTION APPROVAL PRODUCTION APPROVAL LAUNCH APPROVAL LAUNCH APPROVAL PROJECT CLOSURE PROJECT CLOSURE MILESTONES KEY CONTENTS KEY CONTENTS GATEWAYS PHASE PHASE PHASE PHASE 00 Page 15 IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING “QUICK & IDEA CREATION PROJECT OBJECTIVES PRE-LIMINARY BUDGETING “QUICK & DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO” DIRTY” BUSINESS CASE SUCCESS CRITERIA “GO / NO GO” TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & TEAM FORMATION RESOURCE & BUDGET ALLOCATION ROLES & RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS RESPONSIBILITIES VOC (VOICE OF CUSTOMER” SPECIFICATIONS MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT MARKET & SEGMENT ANALYSIS COMPETITOR / COMPETITIVE ANALYSIS PRODUCT & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI & PRICE POSITIONING MARKETING & SALES ANALYSIS RISK EVALUATION ROI VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION VOC & MARKET FINALIZATION PRODUCT SPECIFICATION FINALIZATION TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING TECHNOLOGY FINALIZATION QUALITY FINALIZATION MANUFACTURING FINALIZATION INVESTMENT & RESOURCE FINALIZATION FINALIZATION INVESTMENT & RESOURCE FINALIZATION DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + DEVELOPMENT KICK-OFF COLLABORATIVE INITIATIVES IN-HOUSE + SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF SUPPLIERS/VENDORS + CONSULTANTS and BUSINESS / FINANCIAL/RISKS SIGN-OFF DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM) DESIGN SIGN-OFF DESIGN QUALITY CONFIRMATION (DQCM) ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. ENGINEERING SIGN-OFF PRODUCT VALIDATION (TESTING, HOMOLOGATION) v.s. SEPCIFICATIONS SEPCIFICATIONS PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, PRE-PRODUCTION TRIALS AND VALIDATION PROCESS, QUALITY, RELIABILITY, SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION) SUPPLY CHAIN & LOGISTICS (PRE-PRODUCTION) MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION MANUFACTURING SIGN-OFF PRODUCTION QUALITY CONFIRMATION 2 2 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 MARKETING SIGN-OFF MARKET LAUNCH MARKETING SIGN-OFF MARKET LAUNCH PROJECT CLOSURES ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNT PROJECT CLOSURES ENGINEERING & TECHNICAL PCR/PCO LESSONS LEARNT KNOWLEDGE CAPTURING KNOWLEDGE CAPTURING NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] PHASE PHASE 33 PHASE PHASE 22 PHASE PHASE 11 3 PRODUCT DEVELOPMENT SYSTEM – NPI Process – Relationship with Product’s Complexities COMPLEX PRODUCTS COMPLEX PRODUCTS WITH S WITH IE CLEARLY DEFINED IT CLEARLY DEFINED IV MARKET COMPLEX PRODUCTS CT MARKET COMPLEX PRODUCTS A N REQUIREMENTS WITH REQUIREMENTS TIO WITH DIFFICULT TO DEFINE A DIFFICULT TO DEFINE R MARKET EG T MARKET IN REQUIREMENTS R REQUIREMENTS FO D EE S N ES C NG RO SI P A P RE C TE SIMPLE PRODUCTS IN -S SIMPLE PRODUCTS 11 WITH R WITH FO CLEARLY DEFINED E CLEARLY DEFINED C MARKET EN MARKET U REQUIREMENTS SIMPLE PRODUCTS FL REQUIREMENTS SIMPLE PRODUCTS IN WITH DIFFICULT G WITH DIFFICULT IN S TO DEFINE TO DEFINE EA R MARKET C MARKET IN REQUIREMENTS REQUIREMENTS STRUCTURAL COMPLEXITY FUNCTIONAL COMPLEXITY NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] 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 PROJECT α Model fix Styling SOP Mule Detail design 3M Major freeze Off tool Prototype M/T Ship V/M Production tooling Pilot 14 M Concept Initiation PRODUCT PROPOSAL MARKET PRODUCT INVESTMENT & COST STYLING DESIGN PROTOTYPING TESTING & VALIDATION PROCUREMENT PRODUCTION PREPARATION QUALITY Market Research USPs Total Cost & Investment Styling Concept D&E Overview Homologation Plan New, Mod. or C/Over - Concept Direction STYLING APPROVAL Volume-Price Justification Teardown & B/Marking BOM Cost Target Packaging & Ergonomics DCS & Layout Mule Car Plan Design Validation Plan Sourcing Strategy Location & Layout GD&T Concept Approval MODEL FIX Focus Group Development Schedule BOM & Inv. Review Surfacing & DMU SE, DFMEA & PFMEA Mule Car Mule Car Test Appoint & Cost Review Process Plan Quality Planning Final Approval DQCM Marketing Plan CVDS BOM & Inv. Tracking Colors & Accessories P-Drawings Mule Car Test Results & Validation Final Supply Cost Process Validation Process Control FOLLOW-UP and COUNTERMEASURES Pet Name, Brochures, Launching Program, 7 Manuals Project Progress Follow-Up and Tracking Project Feasibility Tracking (BOM & Investment) Interior and Exterior Colors, Material, Texture Follow-up and Finalization C.L. Tracking and Validation Timely Feedback to Design, Manufacturing Engineering and Quality Timely Feedback to Design, Manufacturing Engineering and Quality Vendors / Suppliers Preparation Progress Follow-up Contractors / Tools Suppliers Preparation Progress Follow-up, Line Training • Validate Vendors Quality Systems • Validate In-House Quality Process Production Approval PQCM Sales & Launch Plan Product Variants OMV & OTR PCR / PCO Cut-off Durability & Reliability PPAP & PSW PSA Final Process Build-up Quality NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 17 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 PROJECT α Model fix Styling Mule Detail design 3M Concept Initiation PRODUCT PROPOSAL Concept Direction STYLING APPROVAL Concept Approval MODEL FIX Major freeze Off tool Prototype M/T Ship V/M Production tooling Pilot 14 M Final Approval DQCM FOLLOW-UP and COUNTERMEASURES Production Approval PQCM 1 CRITICAL MILESTONES INITIATIVES FOR PRODUCTION PREPARATION FOR Project α (Platform Carry-Over) PROJECT TO BE ABLE TO BE LAUNCHED BY 18 MONTHS AFTER MODEL FIX Product Location Approval (including Investment) Production Layout 2 Finalization Appointment of Contractor and Tooling (Dies and Jigs) Suppliers Line Preparation Completion M-Car Production Phased-out Equipment and Facilities Relocation (including for Spare Parts) Line Modification, Construction, Installation, Testing and Validation 3 4 5 6 Appointment of Local Vendors Product and Process Quality Market & Production Quality Feedback SE (Simultaneous Engineering) for DFMEA & PFMEA Quality Planning (GD7T, Fit & Finish, Appearance, BIW, Warranty, Reliability) Lessons Learnt and Improvement NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 18 TYPICAL PROJECT –DEVELOPMENT MAN-HOUR and INVESTMENT Rendering Body Design Clay Modeling • Chassis • Equipment • Electrical • CAE STYLING ENGINEERING ENGINE PROTOTYPE • Benchmarking • Market Research PRODUCT PLANING • Noise Test • Vibration Test • Crash Test • Homologation TESTING • Gurun Alam Plant • Bertam Plant PRODUCTION PREPARATION LOGISTIC ASSEMBLY Engine Design Machining Casting PRODUCT PLANNING MAN HOUR STYLING ENGINEERING PROTOTYPE TESTING PROD. PREP. LOGISTIC ASSEMBLY Average ~ +/- 1.0 Million Man-hour 10 % 25 % 9% 14 % 19 % 11 % 6% 6% COST Average ~ RM 500 ++ Million 2% 22 % 11 % [Company No.: 591026-M] 1% 6% 51 % 5% 2% Page 19 NAZA AUTOMOTIVE MANUFACTURING SDN BHD PROGRESS MONITORING and DECISION MAKING Require ‘top down’ and ‘bottom up’ process. MECHANISM • Monthly Product / Project Committee Review Meeting. • Management Committee Meeting THE MANAGEMENT TEAM (MCM, PDC) PROVIDE STRATEGIC INTENT PROVIDE GUIDANCE DECISION MAKING PROBLEM ESCALATION PROBLEM RESOLUTION PROBLEM IDENTIFICATION THE PROJECT TEAM MEMBERS NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] MONITORING & CONTROL IMPLEMENTATION • Weekly Meeting • Status Reports • Daily Meeting Page 20 COMMON CAUSE OF FAILURES Supplier manpower not consistent Insufficient measurable outputs Supplier under resources Supplier skills oversretched Overall poor management Mismanagement of progress Costs getting out of hand Inadequate coordination of resources Milestone not being met No quality Control Lack of Planning of scheduling, resources and activities Bad Communication between relevant parties 0 4 11 12 13 17 20 26 29 34 35 39 57 10 20 30 40 50 % 60 Source : The Bull Survey (IT Project) NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] 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. • • • • • NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 22 THANK YOU FOR YOUR ATTENTION NAZA AUTOMOTIVE MANUFACTURING SDN BHD [Company No.: 591026-M] Page 23