Rico Auto
Manufacturing Engineering Department
RICO
TURTLE DIAGRAM - PROJECT MANAGEMENT (NEW PRODUCT DEVELOPMENT)
Doc.Number
RICO 14 DOC 03
Rev.No.
Rev. Date
2
19.10.11
SKILLS
Management Skill
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Leadership Skill
Communication Skill
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Technical Skill
Product & Process Knowledge
Knowledge of relevant standards
Change management Skill
Knowledge of Core Tools
Engineering design Skill
Costing Skill
Project Management Skill
PROCESS OWNER
PROCESS Name
: PRODUCT DESIGN & DEVELOPMENT
: HEAD - DEVELOPMENT
: Project Management
(New Product Development)
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Procedure -
¤ RICO18 QSP 01 (APQP / Product Realization / Proj. Mgmt.)
¤ RICO12 QSP 03 (Process for PPAP)
TS Standards
¤ RICO 12 QSP 02 (Process for Process FMEA)
TS 16949:2009
¤ RICO 12 QSP 01( Procedure for control plan)
¤ RICO 12 QSP 04( Procedure for Process Flow Diagram)
INPUT
VARIABLE INPUT
WORK INSTRUCTION/ STANDARDS
- Customer Specific Standard
PROCESS CONTROL PROCEDURE
PROCESS
Product Desgin &
Development
COMMON INPUT
EMS / OHSAS Standards
ISO 14001:2004 / OHSAS 18001:2007
OUTPUT
Plan & Define
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Customer Target Dates
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AIAG Manual
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Packing Standards / Norms
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QEHS Policy
- On time Development of Part as per Customer Requirement
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Business Plan
-On time Completion of RFQ as per Marketing Requirement
Objectives
Customer specific requirements including
Government regulatory requirement
Timely Implementation of ECN
On Time Development of Part
Special Product characteristics
TGW / TGR Reports / PFMEA
Process Design &
Development
Engineering Drawings & Standards
ECN Management
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PROJECT MANAGEMENT
(NEW PRODUCT DEVELOPMENT)
-On time Implementation of ECN as per Customer Requirement
Targets for Productivity , Process capability, Cost
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Customer complaints / Feed back
Bill of Material
Quality rating
APQP Timing Chart
Warranty rating
Lot Rejection PPM / Line Rejection PPM
Feedback & Submission
PPAP Submission
Plant Head
PROCESS OBJECTIVES
PROCESS INTERFACE
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Marketing
Customer Drawings / Customer Specific requirements / Kick-off Dates
Purchase
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Vendor registration / Parts as per BOM
Stores
Issues of Material
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Mainteneance
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EFFECTIVENESS
TOOL ROOM
VENDOR
DEVELOPMENT
¤ Project under taken Plan Vs Timely completed
¤ Capability Proveout Data (Cpk / Ppk)
ENGINEE
R
Master List of Machines / Machine Installation , Machining Capability
Quality & Lab
Test as per control plan/ Inspection Standard
Lab Test Schedules
Performance / Layout reports / MSA
Master List of IMTE / Calibration record
Lab Matrix
PPC
Daily Production Plan as per customer requirement / Capacity utilization
Human Resources
Training / Motivational schemes / Competency / OJT
Project Group Leader- 1
(NPD,RFQ & ECN)
PROJECT
LEADER
ENGINEER
Project Group Leader-2
(NPD,RFQ & ECN)
¤ No. of mistake proofing Plan Vs Implemented
¤ No. of ECN received Vs Timely implementation
¤ No. of RFQ received Vs Timely Completion
EFFICIENCY
¤ Continuous improvement Projects
PROJECT
LEADER
ENGINEER
Govt. / Legal regulation
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Manufacturing Process
ASSOCIATES
Similar Line OEE / Rejection PPM / Rework PPm / Poke Yoke
Tool Room
Tool Maintenance / Master List
19.10.2011
01.07.2011
25.06.2003
ASSOCIATES
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2
1
0
Sl.No
Rev.No / Rev. date
Reviewed & revised
Reviewed & revised
Initial
Revision Details
Prepared By
Checked by
Remarks
Approved By
Turtle Diagram Vendor Development
INTERFACE
COMPETENCE AND SKILL
- QUALITY ASSURANCE DEPTT.
- STORES
- ACCOUNTS DEPTT.
- PRODUCTION, PLANNING & CONTROL
- TRAINING
- MARKETING DEPTT.
- ENGINEERING DEPTT.
- MANAGERIAL SKILL
- COMMUNICATION SKILLS
- PROCESS KNOWLEDGE
- DECISION MAKING
- SUPPLIER DEVELOPMENT SKILL
SUPPLIER SELECTION CRITERIA
PART / SUPPLIER DEVELOPMENT
PLAN TO MEET CUSTOMER
REQUIREMENT
SUPPLIER DEVELOPMENT &
UPGRADATION TO REQUIRED
INTERNATIONAL STANDARDS
AS PER CUSTOMER
REQUIREMENT
CUSTOMER APPROVED SOURCES
SUPPLIER DEVELOPMENT PLAN
TIMELY DEVELOPMENT OF PART / MATERIAL
CONFORMING TO CUSTOMER SPECIFIED
REQUIREMENT, USER SPECIFICATION, AT
OPTIMUM COST
EHS SPECIFIC REQUIREMENT
PROCEDURES
RICO 08 QSP 01 / QSP/RICO GGN/ 06.1
RICO 08 QSP 02 / QSP/RICO GGN/ 06.2
RICO 08 QSP 03 / QSP/RICO GGN/ 06.2
RICO 06 QSP 09 / QSP/RICO GGN/ 16.1
RICO 02 QSP 04
RICO 18 QSP 01
PROCEDURE FOR PURCHASING
PROCEDURE FOR ASSESSMENT & SELECTION OF SUPPLIER
PROCEDURE FOR SUPPLIER DEVELOPMENT
PROCEDURE FOR QUALITY / EHS RECORDS
PROCEDURE FOR RESOURCE MANAGEMENT
PROCEDURE FOR PRODUCT REALIZATION
PERFORMANCE
EFFECTIVENESS
(1) PART DEVELOPMENT COST PLANNED V/S ACTUAL
(2) PART DEVELOPMENT TIME PLANNED V/S ACTUAL
(3) NO OF PARTS DEVELOPED MONTHLY
(4) FAILURE IN PART SUBMISSION TO CUSTOMER DUE
PART NOT DEVELOPED ON TIME
EFFICIENCY
(1) PART DEVELOPED EFFECTIVELY INTERMS OF COST,
TIME & REQUIREMENT
PROCESS OWNER : VENDOR DEVELOPMENT HEAD
Department Functions
►REQUEST
FOR QUOTATION
►TECHNICAL REVIEW
►NEW
WITH CUSTOMER
PRODUCT DEVELOPMENT
►APQP ACTIVITIES
& DOCUMENTS
►PPAP ACTIVITIES
& DOCUMENTS
►ENGINEERING
►DESIGN
CHANGE MANAGEMENT
OF FIXTURES,SPL TOOLS AND SPL GAUGES.
►MANUFACTURING
►VENDOR
OF FIXTURES & GAUGES.
DEVELOPMENT FOR BOP & CASTINGS
►CAPITAL PROCUREMENT
Department Objectives
►MEET
CUSTOMER REQUIREMENTS
►REDUCE
►LEAN
LEAD TIME FOR NEW PRODUCT DEVELOPMENTS
MANUFACTURING
►ELIMINATE
MANUAL OPERATIONS
►REDUCE
CYCLE TIME
►REDUCE
CONSUMABLE TOOL COST
►IMPLEMENT
POKA YOKE.
Schematic of Process flow
Marketing
Received dwg
submit to Customer
Cost Estimation
Feasible
Feasibility
study
Not feasible
Negotiation/Tech.Review
Vendor
Development
Dwg Freeze
BOP Parts
APQP Timing plan & Activities
Sample Dev
Not OK.
PILOT LOT
Customer Feed Mark
Submit to
customer
OK.
Tech.Reveiw
APQP Issues
L.O.I/P.O.Release
SPC STUDY
PPAP
SOP
Key Customer and Products (Domestic)
Differential Case,Fly Wheel Assy
Rotor Oil Filter,Front &Rear Panel,
Alloy Wheel,Crank Case,Front Panel
Forks,Steering Knuckle,
Brake DiscCover Cylinder Head,
Engine Brackets,Case oil Pump Assy.
Brake Drum,Oil Pan.
Crank Case,Clutch Assy,Grip
Rear Panel,Grip
Cylinder Block,Cylinder Head,
Bed Plate,Cover Cyl Head
FiamMinda
Connection Water Out let
Plate EGR,ACG Braket
Stay Front,Cover Cam Thrust
Jerico Body, Housing Regulator
Cap MainBearing,Head Lube Oil Filter
Connection Water Inlet,Head Fuel Filter
Connection Water Out Let
Housing Thermostat,Cover intake
mnfoldCover Rear,Housing Gear.
FCC RICO(JV)
Face Movable Drive,Face Fix Drive
Bracket Rad Lwr
Pressure Plste,Outer Clutch
Engine Bracket
Center Clutch
Turbine Housing, Center Housing
Brace Transmission
FORKS
Bracket Alternator
Balance shaft,Bracket comp p/s pump
Water Pump(Casting)
Tandum Master Cylinder (Casting)
Brake Drum, Brake Disc
Key Customer and Products (Export)
Differential Case
Support ASM FRNT DIFF Trsfr DRV(6F) Bracket alternator
Bracket Fly wheel Sensor
Plate Adaptor
Stay Front,Support Bracket
Oil Filter Head,Timing Gear Case
Base as fuel filter
Pipe Intake,Pipe angle
Manifold,Housing regulator
Base as fuel Head
Manifold,Container cat
Housing Pump,Housing RR Axle.
Cover side,Base rocker arm
Cap Main Bearing,Exhaust Manifold
Retainer bearing bracket
Piston bearing break
Bearing Caps
Support Seal RING,Housing Pump
Pressure plate,Intermediate Plate
Engine support brACKET
Rear case,Front Case.
Housing
Connection water Inlet
Connection water outlet
Turbine Housing,Center Housing
Support Alternator
Housing thermostat
Connection Fuel Block