Mazda Monotsukuri Innovation and
Further Advance by Using Manufacturing
and Market Big Data
1. Mazda’s target image and Monotsukuri Innovation
2. Further advance of Monotsukuri Innovation
・ Seamless Monotsukuri by using big data
・ Building block structure for Monotsukuri Innovation
3. Examples
December, 1st 2015
Iwao AOTA
Production Engineering Division
Mazda Motor Corporation
1. Mazda’s target image and Monotsukuri Innovation
Target of brand position
Common architecture
concept
Production
Next Step
Customer Value
Monotsukuri
Innovation
Bundled Plan
Development
Flexible production
concept
Next Step
Enabler
Connect by big data and
advance BOM
“Bundled Plan”
Advance Monotsukuri by
seamless MBD
Business Efficiency
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2. Further advance of Monotsukuri Innovation
Seamless Monotsukuri by using big data
Pursue customer’s true value
What MBD means?
Functional model
IN
Industry 4.0
Part C
OUT
Input
OUT
→
Market data
Part B
Part A
OUT
Manufacturing
data
IN
→
Output
IN
※MBD: Model Based Development
Industry 3.0
+
Industry 2.0
Industry 1.0
出展：Recommendations
for
implementing the strategic
initiative INDUSTRIE 4.0
Connect by big data and
advance BOM
Advance Monotsukuri by
seamless MBDMazda Motor Corp.│ Strictly Confidential │ 2
2. Further advance of Monotsukuri innovation
Monotsukuri Innovation Building Block Structure
Seamless MBD
Pursue customer’s value by using
big data
At
Present
Pursue structure by bundled plan
Future
Systemized Iot business
model
Pursue “Manufacture only one vehicle with
full of heart for customers”
【Achieve zero defect (100-1=0) 】
Monotsukuri Innovation Building Block Structure
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3. Example #1: Using production big data and market big data
Improve warming characteristics(fuel efficiency) by using engine manufacturing data
and market data (VOC monitor).
【VOC monitor result】
There is a difference of the water
temperature(warming).
Water
Temp.
（）
℃
Mr. B
Mr. A
⇒
Time(sec)
⇒
Time(sec.)
Confirm warming effect for cooling water circulation by actual vehicle
Radiator IN
flow
meter(hot)
【Accumulation of engine production data】
【Advance of warming system】
(Current) Thermostat => (Advance) water flow control valve engine to improve
warming characteristics(fuel efficiency)
Fuel efficiency
Warm up combustion chamber promptly to reduce variation.
）
(L/H
N=56
Verification for water flow control
Thermostat verification
70
84
40
82
80
78
76
74
72
1
2
⇒
3
4
Time(sec)
5
6
7
8
9
10
11
12
1085.0
1080.0
60
86
Difference of
thermostat
opening speed
30
1100.0
1090.0
Water Temperature
1075.0
50
Water
Temp （℃）
1105.0
1095.0
80℃
80
THW
Higher warming makes better fuel efficiency
⇒ Warming characteristics∝fuel efficiency
W/O water flow control
W/water flow control
90
Water Temp.（℃）
Fuel histogram
Thermostat +
Warming
control
Radiator IN
flow
meter(cold)
Reduce 9%
1070.0
1065.0
Improve 1/3 of
variations
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3. Example #2: Using manufacturing big data and vehicle
characteristics measurement
Body manufacturing data and vehicle characteristics measurement by DDRS
※DDRS: Diagnostic Data Record System
Future
Mazda
Body manufacturing data accumulation
Measurement of vehicle characteristics
(Create big data of customer value)
Measurement by DDRS
More than thousands of CAN data can be
obtained
Correlation between
steering angle and yaw rate
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Image of final target
Use big data of manufacturing & market data fully by IoT
and maximize customer value
Customer’s
vehicle
Customers
CAN - bus
・smart phone
・PC
OUTPUT
7”
・Maintenance proposal
・New vehicle
replacement proposal
CMU
Media Hub
Vehicle
information
●
ＣＭＡ
●
AAT
Japan
・smart phone
・vehicle-mounted
communication
device
Mazda
●
INPUT
R&D, manufacturing information
OUTPUT
・current model
improvement
・new vehicle
development
・production
improvement
etc.
・Proposal how to use car
Dealers
・Proposal how to drive
・Event information
●
・Set up remote navigation
etc.
MMVO
・information of unit and purchased parts
・raw material, process, assembly
・components, characteristics, production lot,
production conditions, control characteristics
measurement result, etc.
・vehicle information
・stamping, body, paint, final assembly
・production lot, production conditions, control
characteristics measurement result, inspection
result, etc.
Mazda(R&D,
manufacturing)
Data base
Vehicle information
Data base
INPUT
Information of vehicles and
customers
Locating information, driving distance,
warning record, maintenance record,
purchasing record, fuel efficiency, etc.
6
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Thank you.