Rico Auto

Manufacturing Engineering Department

 Doc.Number RICO 14 DOC 03
RICO TURTLE DIAGRAM - PROJECT MANAGEMENT (NEW PRODUCT DEVELOPMENT) Rev.No. 2
Rev. Date 19.10.11
SKILLS
Management Skill Technical Skill PROCESS CONTROL PROCEDURE WORK INSTRUCTION/ STANDARDS
¤ Leadership Skill ¤ Product & Process Knowledge PROCESS : PRODUCT DESIGN & DEVELOPMENT ¤ Procedure - - Customer Specific Standard
¤ Communication Skill ¤ Knowledge of relevant standards PROCESS OWNER : HEAD - DEVELOPMENT ¤ RICO18 QSP 01 (APQP / Product Realization / Proj. Mgmt.)

¤ Change management Skill PROCESS Name : Project Management ¤ RICO12 QSP 03 (Process for PPAP) TS Standards
¤ Knowledge of Core Tools (New Product Development) ¤ RICO 12 QSP 02 (Process for Process FMEA) TS 16949:2009
¤ Engineering design Skill ¤ RICO 12 QSP 01( Procedure for control plan)

¤ Costing Skill ¤ RICO 12 QSP 04( Procedure for Process Flow Diagram) EMS / OHSAS Standards
¤ Project Management Skill ISO 14001:2004 / OHSAS 18001:2007

INPUT Product Desgin &

VARIABLE INPUT COMMON INPUT Development OUTPUT
Plan & Define

¤ QEHS Policy - On time Development of Part as per Customer Requirement

¤ Engineering Drawings & Standards

¤ Business Plan -On time Completion of RFQ as per Marketing Requirement
¤ Customer Target Dates ¤ Objectives

ECN Management

Process Design &

Customer specific requirements including
¤ -On time Implementation of ECN as per Customer Requirement

Development
Government regulatory requirement Timely Implementation of ECN
¤ AIAG Manual On Time Development of Part PROJECT MANAGEMENT
¤ Special Product characteristics
(NEW PRODUCT DEVELOPMENT)
¤ TGW / TGR Reports / PFMEA

¤ Targets for Productivity , Process capability, Cost

¤ Packing Standards / Norms

¤ Customer complaints / Feed back
¤ Bill of Material Quality rating
¤ APQP Timing Chart Warranty rating Feedback & Submission
PPAP Submission
Lot Rejection PPM / Line Rejection PPM

Plant Head
PROCESS OBJECTIVES
PROCESS INTERFACE
¤ Marketing EFFECTIVENESS
Customer Drawings / Customer Specific requirements / Kick-off Dates
¤ Purchase TOOL ROOM
VENDOR
DEVELOPMENT
Vendor registration / Parts as per BOM ¤ Project under taken Plan Vs Timely completed
¤ Stores ¤ Capability Proveout Data (Cpk / Ppk)
Issues of Material ¤ No. of mistake proofing Plan Vs Implemented
ENGINEE
¤ Mainteneance R
¤ No. of ECN received Vs Timely implementation
Master List of Machines / Machine Installation , Machining Capability ¤ No. of RFQ received Vs Timely Completion
¤ Quality & Lab
Test as per control plan/ Inspection Standard Project Group Leader- 1 Project Group Leader-2
Lab Test Schedules (NPD,RFQ & ECN) (NPD,RFQ & ECN) EFFICIENCY
Performance / Layout reports / MSA ¤ Continuous improvement Projects
Master List of IMTE / Calibration record
Lab Matrix PROJECT PROJECT
LEADER LEADER
¤ PPC
Daily Production Plan as per customer requirement / Capacity utilization
¤ Human Resources
ENGINEER ENGINEER
Training / Motivational schemes / Competency / OJT
Govt. / Legal regulation

¤ Manufacturing Process
ASSOCIATES ASSOCIATES
Similar Line OEE / Rejection PPM / Rework PPm / Poke Yoke

¤ Tool Room
Tool Maintenance / Master List
2 19.10.2011 Reviewed & revised
Prepared By
1 01.07.2011 Reviewed & revised
0 25.06.2003 Initial Checked by
Sl.No Rev.No / Rev. date Revision Details Remarks Approved By

INTERFACE
- QUALITY ASSURANCE DEPTT.
- STORES
- ACCOUNTS DEPTT.
- PRODUCTION, PLANNING & CONTROL
- TRAINING
- MARKETING DEPTT.
- ENGINEERING DEPTT.
SUPPLIER SELECTION CRITERIA
PART / SUPPLIER DEVELOPMENT
PLAN TO MEET CUSTOMER
REQUIREMENT
CUSTOMER APPROVED SOURCES
SUPPLIER DEVELOPMENT PLAN
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
PROCESS OWNER : VENDOR DEVELOPMENT HEAD
Turtle Diagram Vendor Development
COMPETENCE AND SKILL
- MANAGERIAL SKILL
- COMMUNICATION SKILLS
- PROCESS KNOWLEDGE
- DECISION MAKING
- SUPPLIER DEVELOPMENT SKILL
SUPPLIER DEVELOPMENT &
UPGRADATION TO REQUIRED TIMELY DEVELOPMENT OF PART / MATERIAL
CONFORMING TO CUSTOMER SPECIFIED
INTERNATIONAL STANDARDS
REQUIREMENT, USER SPECIFICATION, AT
AS PER CUSTOMER OPTIMUM COST
REQUIREMENT
PERFORMANCE
PROCEDURE FOR PURCHASING EFFECTIVENESS
PROCEDURE FOR ASSESSMENT & SELECTION OF SUPPLIER (1) PART DEVELOPMENT COST PLANNED V/S ACTUAL
PROCEDURE FOR SUPPLIER DEVELOPMENT (2) PART DEVELOPMENT TIME PLANNED V/S ACTUAL
PROCEDURE FOR QUALITY / EHS RECORDS (3) NO OF PARTS DEVELOPED MONTHLY
PROCEDURE FOR RESOURCE MANAGEMENT (4) FAILURE IN PART SUBMISSION TO CUSTOMER DUE
PROCEDURE FOR PRODUCT REALIZATION PART NOT DEVELOPED ON TIME
EFFICIENCY
(1) PART DEVELOPED EFFECTIVELY INTERMS OF COST,
TIME & REQUIREMENT
 Department Functions

►REQUEST FOR QUOTATION

►TECHNICAL REVIEW WITH CUSTOMER

►NEW PRODUCT DEVELOPMENT

►APQP ACTIVITIES & DOCUMENTS

►PPAP ACTIVITIES & DOCUMENTS

►ENGINEERING CHANGE MANAGEMENT

►DESIGN OF FIXTURES,SPL TOOLS AND SPL GAUGES.

►MANUFACTURING OF FIXTURES & GAUGES.

►VENDOR DEVELOPMENT FOR BOP & CASTINGS

►CAPITAL PROCUREMENT
 Department Objectives

►MEET CUSTOMER REQUIREMENTS

►REDUCE LEAD TIME FOR NEW PRODUCT DEVELOPMENTS

►LEAN MANUFACTURING

►ELIMINATE MANUAL OPERATIONS

►REDUCE CYCLE TIME

►REDUCE CONSUMABLE TOOL COST

►IMPLEMENT POKA YOKE.

 Schematic of Process flow

Marketing submit to Customer Negotiation/Tech.Review OK.

Received dwg Cost Estimation Vendor Not OK. Tech.Reveiw

Development APQP Issues

Feasible BOP Parts Dwg Freeze L.O.I/P.O.Release

Feasibility APQP Timing plan & Activities PILOT LOT SPC STUDY
study

Not feasible Sample Dev Customer Feed Mark PPAP

Submit to SOP
customer
 Key Customer and Products (Domestic)

Differential Case,Fly Wheel Assy
Forks,Steering Knuckle,
Brake DiscCover Cylinder Head,
Engine Brackets,Case oil Pump Assy.
Brake Drum,Oil Pan.
Connection Water Out let
Plate EGR,ACG Braket
Stay Front,Cover Cam Thrust
Rotor Oil Filter,Front &Rear Panel,
Crank Case,Clutch Assy,Grip
Cylinder Block,Cylinder Head,
Bed Plate,Cover Cyl Head
FiamMinda
Jerico Body, Housing Regulator
FCC RICO(JV)
Alloy Wheel,Crank Case,Front Panel
Rear Panel,Grip
Cap MainBearing,Head Lube Oil Filter
Connection Water Inlet,Head Fuel Filter
Connection Water Out Let
Housing Thermostat,Cover intake
mnfoldCover Rear,Housing Gear.

Face Movable Drive,Face Fix Drive

Turbine Housing, Center Housing
Bracket Rad Lwr Pressure Plste,Outer Clutch
Engine Bracket Center Clutch
Brace Transmission
Bracket Alternator FORKS
Water Pump(Casting)
Balance shaft,Bracket comp p/s pump

Tandum Master Cylinder (Casting)

Brake Drum, Brake Disc
 Key Customer and Products (Export)
Differential Case
Plate Adaptor
Base as fuel filter
Manifold,Housing regulator
Cover side,Base rocker arm
Retainer bearing bracket
Piston bearing break
Bearing Caps
Support ASM FRNT DIFF Trsfr DRV(6F) Bracket alternator
Bracket Fly wheel Sensor
Stay Front,Support Bracket
Oil Filter Head,Timing Gear Case
Pipe Intake,Pipe angle
Manifold,Container cat
Base as fuel Head
Housing Pump,Housing RR Axle.
Cap Main Bearing,Exhaust Manifold
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