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Hicom Teck See Manufacturing Malaysia Sdn.Potential analysis for localization Bhd.
Lot 76 & 75A, Jalan Sementa 27/91, Section 27, 40000 Shah Alam, Selangor, VW 250 G (RL IN) Malaysia
Rating scale first development (Tier 1): A = 90 - 100% B = 75 - 89% Development capability fulfilled Development capability partially fulfilled Development capability not fulfilled
Audit Result
Component/Product Group
(with product technology)
C=
< 75%
Part number
6RU 867 011
Assessment
First Development
(Forward Sourcing)
Second Development
(Global Sourcing)
74%
Capable
Products
No of Employees
648
FE
JV-Partner
23
Date:
24.09.2010
Walenkamp, Gijs (K-ESB - TE-Auditor) Name, Organisation, Auditor Signature Terence SOO Thean Hin (COO) Name, Company Signature Niedenfuehr, Sven (EKKF/2)
Distributor:
Lauck, Joachim (K-ESB) Utzeri, Giancarlo (K-ES/B1) Nazare, Anja (K-ESB) Pritzke, Jens (K-ES/B1)
Poerksen, Maik (VWG Malaysia) Che, Fong Mei (VWG Malaysia) Werner, Thorsten (EKKF) Raguse, Michael (EKP/Z)
Form responsibilitiy: Volkswagen AG, K-ES TE-Lieferantenbewertung, Brieffach 1446, 38436 Wolfsburg, Deutschland Change status 01.11.2008 (A4-Format)
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Technology
Remarks
Various
No Product: Middle group: Date: Rating result: Part-Number.: 6RU 867 011
Part name:
30
40
50
60
70
80
90
100
30
Result analysis:
50
194 260*100 180
70
74%
90
C capable
Forward Sourcing
(new Product Design)
Result = Result =
Global Sourcing
(without new product design)
Points
Participants:
Hicom Teck See Manufacturing Malaysia Sdn. Bhd. Terence SOO Thean Hin (COO) Sarly Adle Bin Sarkum (Head of Division Bus.Dev.) Yohan bin Mokhtar (Senior Manager Veh.Man.Proj.) Lim Sheng Shun (Senior Manager Prod. Planning) Azmi Wahap (Manager Autom.Comp.&Eng. Division) Yau Kian Min (Manager Bus.Dev. Division) Adam Mat Robi (Manager Project Development) also with the participants from DRB-Hicom Headquarters
Volkswagen AG Walenkamp, Gijs (K-ESB - TE-Auditor) Poerksen, Maik (VWG Malaysia) Che, Fong Mei (VWG Malaysia)
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Hicom Teck See Manufacturing Malaysia Sdn. Bhd. 6RU 853 651 ASSY Radiator GrilleTrim 867 011 ASSY Door 6RG
Points
6R0
807
221.D
1.
Has the development partner all the required specifications and environment standard
VW99000: available, content unknown B2B access incl. ESL available, person responsible: Project manager B2B contents should be centrally file and all involved project to be provided
2.
2.1
2.2
Has the development partner CAD System compatibility acc. To VW AG (VW01059) and actual System guidelines Yes, should: Catia V5 R19
20
2.3
Is the development partner using innovative Construction and Simulations method: Plastic full simulation and warping: moldflow-analysis would be performed via tools manufacturer; Documentation available
10
FE Simulation to vehicle occupant protection (ECE, FMVSS, EuroNCAP), head impact, modal analysis and acoustic (NVH), misusage: all about OEM/Customers CAE: Know-how limited availability, proposed amendment to optimise tooling come from tools supplier
2.4
Has the development partner DF (Data Transmission) and Data Check Module for drawing exchange
DF: Design data management system not available VW-compliant data check module: End check & Validity: Catia V5 R19 not available o
0 .
(max. 50 Points)
.
0 16 24 32 40
3.
3.1
Overall-design: 3Employees (CAD) / CAE: 0 Employee / Project management: 6 Employees as Programme manager plus 14 Product engineers
3.2
If 3.1 =< 24, has the development partner access/grasp to alternatives (foreign capacity):
12
16
Tools supplier (e.g Moltec, DongWang, Hanguk from Malaysia, Korea, Taiwan) IDIADA (Spain): Head impact FEM-Analysis
3.3
10
Based on Class A-Surface-Data, component construction at OEM proton on site are performed by 3 of Hicom Teck See employees. At visited headquarters: CAD Data and drawing management / dissemination at tools supplier Employee qualification : current state matrix, without forecast CAD-Data storage needs to be improved (Stucture, partial disk, CD-Rom)
3. Result (max. 50 Points) 0 4 6 8 10
4.
Used weld technology I-Panel:US-welding (2x), HSK: Hot-Plate welding, no laser trimming or Waterjet available, manual trimming support plate door trim Plastic: resin --> local resin supplier (see data sheet) Processes: Plactics IM, Blow Molding, no Slush or material after spraying, manual painting at location, using Robot in Thailand branch, Chrome: currently external supplier, internal facility will be establish in 2011 (micropores) 4. Result (max. 10 Points)
.
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6RU 867 011 Hicom Teck See Manufacturing Malaysia Sdn. Bhd.
Points Points Points Points Points
5.
5.1 a) b) c) d) 5.2 a) b) c)
Testing
Has the development partner appropriate test capabilities for functional testing: EP 84110.01: Push in / push out forces / Tear off test of fasteners (RT) --> external institute or OEM EP 84610.10: Function Test: load on arm rest / door tray --> external institute or OEM EP 84610.12 /EP85550.22: Buckling resistance of trim panel and door tray (RT,+70 C) EP 85550.30: Ball drop test on loudspeaker grill (M=0,5 kg RT-10 PV3905) --> external institute or OEM C, EP 85550.70: Misuse by forces up 500 N on mesh, door tray box under RT-30+70 --> external institute or OEM C Present : Gauges. Has the development partner appropriate test capabilities for continuous testing :
Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)
0 0 0 0
8 8 8 8
12 16 12 16 12 16 12 16
20 20 20 20
1 1 1 1
EP 84610.21: continuous load of arm rest and door handles (steel ball, 150 N, N=10000, -30+70 --> external institute or OEM C) EP 84610.50: Temperature aging +LF--> climate chamber (-30+100 C+LF, 48h) -> 1x Climate chamber (-30+177 C+LF) EP 84610.51: climatic cycle---> climate chamber (PV2005) -> 1x Climate chamber (-30+177 C+LF) EP 85550.10: Door closing Function test by pulling on tray (150N, -30+70 N=1000) --> external institute or OEM C, High temp. lightfastness (PV1303, 5 cycles, 100 CXenontest=solisi) --> external institute or OEM
0 0 0 0
8 8 8 8
12 16 12 16 12 16 12 16
20 20 20 20
1 1 1 1
5.3 a) b) c) d)
Present : Dimension, Weight, Measuring table, auto. 3D measuring machine (unexact, +/- 0.1 mm). External : Flammability (TL1010) Material e.g PP : Emission behaviour, Fogging (VW 50180), density, yield stress, elongation, ball indenation hardness, melting temp. Continuous monitoring relevant : Present --> Glossmeter Checking gauge in plastic plant : Present --> Single part and Assy
0 0 0 0
8 8 8 8
12 16 12 16 12 16 12 16
20 20 20 20
1 1 0 0
5.4
Has the development partner sufficient testing capacity: Significant amounts are performed externally
20
5.5
If 5.4 = 0, has the development partner access to alternative (foreign capacity): external Institute : e.g. TV Singapore, IDIADA, local OEM Proton
12
16
5.6
The development partner has sufficient testing competency: Present : Detailed testing plan, testing specification and documentation Present : Calibrated and documented measuring devices / no temperature controlled measuring room Gauges are used for measuring test part 5. Results (max. 50 Points)
10
0 8 12 16 20
6.
6.1
Prototyping
Has the development partner an adequately equipped and organizationally independent prototyping: Organizationally not independent. Plastic parts are manufactured on original equipment, assembly and construction prototypes in production 1 room for master sample storage Documentation as per PPAP-Document (Measuring report, test report)
6.2
Has the development partner sufficient prototyping capacity: Manufacturing and supplier for single part
20
6.3
If 6.2 = 0, has the development partner access to alternative (foreign capacity): Suppliers of component parts
12
16
6. Results
(max. 40 Points)
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Hicom Teck See Manufacturing Malaysia Sdn. Bhd. 6RU 867 011 ASSY Radiator GrilleTrim ASSY Door 6RG 853 651
Points
Points Points Points Points
6R0
807
221.D
7.
7.1
7.2
Can the development partners set schedules with milestones and resource allocation and ensure the execution of changes 0 4 6 8 10
Processes and to PM clearly defined / structured customized centralized project storage at the server / schedules using MS Project Milestones customer, without critical path with filling) / Open-point list available For under development project, project rooms are set up (currently as Proton, Honda) No holistic resource planning across projects / Change Management: Process standard exists, change pass transparent and complete. 7.3 Is direct communication (without translation) possible: English 0 4 6 8 10
7.4
Is it possible to carry out a development at customer's premises Currently no Resident Engineer near Wolfsburg 7. Result (max. 30 Points)
8.
9.
Assessment Result
Remarks
The company is requested to resolve the following weaknesses: - Study the contents of B2B-Portal (Supplier manual, norm portal, VW99000) - Ensure access to KVS - Advance their know how in terms of component design and tool-based design (plastic parts, steering wheel frame) - Advance their know how in terms of FEM-methods - Improve CAD-data storage - Implement capacity planning - Expansion of test facilities according to part testing specification (Special climate chamber, -40 C / upgrading auto. measuring machine including Scanpack / material analysis) - Improvements in production samples (space, processes, storage, workstations, packaging ...) - Advance know how product development methods (D-FMEA, QFD, DOE) The company was advised that a pro-active communication is required with the operating department The project organization (organization, contact person, position and contact information) is to be presented (including any changes) at initial project. At regular time intervals (agreed with the department) significant schedules, to-do lists and meeting of minutes should be provided. . In addition the supplier was informed that the next TE capability audits and project-specific performance rating be pronounced by the department. An improvement plan must be presented upon nomination within 14 days after receiving of this report.
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