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3D

S.C

OM

© D

assa

ult S

ystè

mes

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onfid

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l Inf

orm

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10/7

/201

3 | r

ef.:

3DS

_Doc

umen

t_20

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Cost Planning

Takashi Tanaka

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Price for Developing Country

Asahi News Paper, DIGITAL 2012, 5, 24 2013, 3, 25 NIKKEI BUSINESS

Tata Nano

Bajaj RE60

VW

Mobius

Logan Indian Market Vehicle $ 8,300

Toyota Etios ① Nissan

Datson Honda BRIO ②

Suzuki

Alto Hyundai

Eon Ford

Figo

Tata Nano ③

Datson unveil on 2014

$ 5,000

$ 2,000

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1 Explanation of Cost Planning

２ To execute Cost Planning

３

Functional design to reduce cost 50% ４

Systems engineering

５ Q&A

Agenda

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Cost Management

Development phase

(Month) -20 -10 0

New automobile

development

Product

Cost

Planning Develop, Test Prepare Production

Design freeze

Cost

Planning

Cost management

Cost reduction activity Cost sustaining

Cost improve

Accepting phase

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Cost Structure

Detail Example

To

tal P

rod

uct C

ost/ V

eh

icle

Mate

rial

Material Metal sheet, paint, etc

Purchasing Tire, audio, purchasing parts

Scrap, Defect Material, defect parts, scrap

Lab

or &

oth

ers

Pro

du

ctio

n

Direct labor Payment, bonus, etc

Depreciation, tax, insurance Building, facility, tools

In-d

irect

Indirect material Tools, oil

Purchasing Building, machine repair, maintenance

Other personnel expenses Travel, transportation

Energy Electric, air

In-direct Production engineering

Development Design, development, evaluation & test

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Current New （Added more new

features）

Target Cost Purchasing & Suppliers -3%

Cost Planning

-30%

Sales Price

Target Setting

Cost

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Bad Cost Reduction Activity

Low possibility.

Unclear results Heavy

Work-load

Current Rough

estimation

Cost reduction

activity VE: Value Engineering

VE

VE

VE

VE

Target Cost

Added Cost （New feature）

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1 Explanation of Cost Planning

２ To manage Cost Planning

３

Functional design to reduce cost 50% ４

Systems engineering

５ Q&A

Agenda

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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

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Physical Oobeya: Basic Layout

Cost

Invest

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Goal of Digital Cost Planning

Reduce the time for DR: 5-days -> 2-hours

Reduction of development lead-time

Improve design quality

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1 Explanation of Cost Planning

２ To manage Cost Planning

３

Functional design to reduce cost 50% ４

Systems engineering

５ Q&A

Agenda

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Systems Engineering

Test

Logical

Requirement

Function

Logical

Test

Evaluate

Integrate

Function

Requirement

Evaluation

Integrate

Development Process

Physical

Digital Actual

Sys

tem

dec

om

po

siti

on

Electric S/W Mecha.

Total

Sub-System

Functional

Mock-up

System

Sub-

System

Component

Entire

Vehicle

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Digital Design Review

Digital mock-up Functional mock-up

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Definition of RFLP

Requirement Function Logical Physical

Market

Expectation Function Structure Component

Mechanical

User’s view

• Quantified

specification

• Parameter

• Definition of Input/

Output

• Device

• Measures • Detail design

Electric

• Plan & Circuit

• Architecture

• Schema

• Collaboration with S/W

• 3D Wiring

• Tubing

Software • Architecture

• Interface • Source code

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Decomposition of Sun-roof

Requirement Function Logical Physical

Light

Cool

Sun light

Control light

Temperature

Shut out

Weight

Handling

Cost

NVH

Open/Close

Safety

Glass

Frame

Drive

・・・

・・・

・・・

External parts

Internal parts

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1 Explanation of Cost Planning

２ To manage Cost Planning

３

Functional design to reduce cost 50% ４

Systems engineering

５ Q&A

Agenda

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Function 動 ｶﾞﾗｽ ﾌﾚｰﾑ Current

Safety 80 10 20 110

NVH 20 20

Open/ close 120 100 220

Sun light 10 10

Control light 10 10 20

Shut out 10 10

Temperature 5 5 10

Cost $210 $45 $145 Total $400

Sun-roof

Drive Glass Frame

By Function- Cost, make Cost Reduction scenario

After

50

20

90

10

20

10

10

Total $200

-50% Reduction

•Competitor is only $90,

Bench marking

• Completely new design

•Shocked about safety cost

• Change design concept

• Simulation effectively

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Opportunity to Improve

Over expectation of Drivability and Quality：

Change design concept completely

Barrier of KEIRETSU：

New and open relationship with suppliers

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RFLP of Sun-roof

Scenario of Demo

Function- cost decomposition

Reduced 50% cost

But +20Kg by using big vehicle’s

Overturned by simulation

Function- cost Consider differently

No problem by simulation

Reduced 50% cost

Only +5Kg Design change

Confirm design of sun-roof

１．Using a carried over

２．New design

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Cost Reduction Target: Break down Input in CAD

Requirement Function Logical Physical

F1

L2 R2

L1 R1

F2 R3 L3

P1

P2

Trade-off

Common

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Cost Reduction -50% １．Reduced cost using a carried over of sun-roof

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Simulation

Rem: Follow up later items is establish another f ile, GM checks w eekly.

Design Check SheetEng Type Parts# Depart R Ｇ

Factory Car Type Name Outside design request #:

Distribute Other Other Design change #:

Requested section Document, Memo CE agree GM Leader Establish

Order Final

M D M D M D M D

Planning Cost Estimated Weight min min min Inspect drawing

Drawing 　 Purchase, Fin

Change drawing 　 Cost Planning Y - N Y - N Y - N with leader

Outside design $ 　 Outside g Final audit of draw ing

Recognized draw (+ - %) 　( ) (+ - %) 1. No problem

Others Background, Objective 2. No confirmation, but no problem

　　Change spec 　　Commonalization　　　Reduce weight 3. There is issue, but go

Durability, Reliability check 　　Research 　　Performance 　　　Productivity 　　What is issue?

Item Count Check 　　VA, VE 　　Solution of Issue　　　Service efficiency

　　　Others

Continue hi-speed Explain:

If it needed, Full throttle U/D Contents of change, Problems by GM Attachment Planning f igure

distribute to Low sw eep U/D Engineering check sheet

production Total pattern Objective, reason by GM Required specif ication

engineering Total temperature 　　Performance 　　Solution of Issue 　　NV improve　　contact issue 　　Others ( 　　　 　　 )

of each factory Low temperature 　　Request from others (CE, Production)　　Commonalization 　　Service efficiency 　　Reduce weight

Ex main temp. 　　Cost reduction　　SOC problem　　Others( )

Long drive

Hammering Contents of change 1.SOP phase

Stresses 2.Target cost

Resonance 3.Current

Dirt course 4.Supplier estimate

Hi-speed reliability 5.Gap

Heat test Anxious by change Countermeasure 6.Countermeasure

Body test Prototype

CAE Stress 1.Parts cost

2.Mold

3.Total

Reflect for test (Left table) Reflect to production Weight

1.SOP phase

2.Target cost

3.Current

4.Supplier estimate

If necessary 5.Gap

internally, Later Recognized draw ing Plan ( / ) Plan ( / ) 6.Countermeasure

OR Follow up ( Y - N ) M D M D M D M D

Copy 　N Check grade Check 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: -- 　 Saf ety issue (FH, Crash, OR, Leak) Row material, process with prod. Eng & supplier

Not accept: Blank Conf irmation Engineering check sheet 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 Env ironmental condition & inf luence

　 Conf lict of parts, distance, slack, f astened, seal 　Oil, water & gas temperature, f rozen, f uel, etc

　　　Caulking, weld, press, insert choking

Information Roll out other model(Y N), Influence other organization(Y N), informed(Y N):

Leader comments:

Total

#1: Each engine & using area has template 　 Check sub-design check sheet of back side

(Revised '05 June) #2: Attach engineering check sheet

Cost

Item Item

FaceEngine Related

FinalOrder

Route: Design room -> Manager ->each CE2- copy for group

１．Reduced cost using a carried over of sun-roof

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Design Change

導風開口面積と最大高さh

75cm2 ：80mm

100cm2 ：130mm

125cm2：150mm

L

F Drive Glass Frame Total

Safety 80 10 20 110

NVH 20 20

Open/Close 120 100 220

Sun light 10 10

Control Light 10 10 20

Shut out 10 10

Tempere. 5 5 10

Total ＄210 ＄45 ＄145 ＄400

２．Change design concept completely, using a new design and reduced cost

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Simulation after design change

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%

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Expecting Target

A bit higher price level

Accomplish quality target －Systems Engineering to reduce cost

－Using simulation effectively

－Quality into Process

Quality

Price

Target

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Summary

Cost Planning to reduce product cost of >30%

Change working behavior and habit

Global and collaborative activity

Functional design to reduce cost 50%

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