Commercial Vehicle Development System 305e6g
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Commercial Vehicle Development System Manual CVDS 3.0
For internal purposes only
/Impressum OMCD Global Process & Project Management Office Daimler Trucks Kevin Bangston Phone +49 (711) 17 39099 [email protected] Stuttgart, November 2011 Kevin Bangston
Dr. Jens Krüger Joachim Mewis Elke Piepenbring Martin Schneider
Phone +49 (160) 8670418 Phone +49 (151) 58613259 Phone +49 (151) 58612597 Phone +49 (160) 8630780
Publisher: Daimler AG Editor: Dr. Jens Krüger, Torsten Awolin Edition 1 (12/2011): 2.000 Ex.
[email protected]
Operational Management Counsel Department (OMCD) Mercedes-Benz Untertürkheim Plant Daimler AG 001 – E202 70546 Stuttgart/ https://sp.app.corpintra.net/sites/00019/CVDSSTandards/ Pages/Startpage_CVDSWiki.aspx
For internal purposes only. All rights reserved. Copying of content, even if only in excerpts, requires a written permission.
Daimler Trucks | 2
Manual Commercial Vehicle Development System 3.0 OMCD – Truck Operating System.
CVDS 3.0 Worldwide – Goals – Content - Benefits Goals – Content • • • • • •
Benefits
Provide methods for integrated planning, steering and • Processes have been optimized: reporting of product projects Early phases (Frontloading), Specification process, release-logic, series and Increase transparency within truck and aggregate projects development suppliers. Worldwide standardization of the product creation • Planning, reporting and steering is integrated into an all process. embracing project management. Continuous improvement of the product creation process by product project application and role specialists. of cooperation and teamwork between and within the projects Develop and guarantee a homogenous understanding on international level.
CVDS 3.0 is the fundamental approach on how we set-up, control and deliver all product projects in Daimler Trucks. From each project lead and project team I expect a selfcommitment to align to this standard. Project specific deviances are to be shown by risk management, in order to treat them with awareness and responsibility.
Stuttgart, November 2011 Andreas Renschler
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Content of the CVDS 3.0 manual 1.
Page Goals and principles of CVDS 3.0
1. Overview
1. Overview
6
2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/ 32 roles
9
2.2.
Quality Gates for truck- und aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks over time
36
2.4.
Main topics and details
69
Planning Assessment Reporting Steering
87 90 95 97
2. P
2. Product creation process (P)
3.1 3.2 3.3 3.4 s
3. Methods
3. Methods
99
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CVDS Product Creation Process • What must be done?
Methods of the Daimler Trucks PM Office • How must it be done?
Lean Project Management Integration of 12 PM modules into the CVDS Framework
• 9 Lean Principles
• When does it have to be done? • Lean Processes (Frontloading etc.)
• Methods
• Quality Gates / Milestones
• Standards
• Process Modules and Steps
• Templates and Guidelines
• Knowledge Database
• Reporting
Leadership Marketing
Objectives
• Best Practices Change Mgnt.
S
10
9 Dt T 1
2
8
7a
7
6
5
4
3
2
1
0
3
Organization
Planning Definition Initialization
„
Steering
1. Overview
Process-oriented integration of PM-methods
Maturity 22
11
33
Organization
Targets 55
66
Time Planning
Project Structure
Risk Management
Resources 10 10
Comm.
88
77
99
Risk Mgnt
44
Costs
Structure
Communication
11 11
Costs
Scheduling Resources
Change / Configuration
Maturity Management
Project Marketing
12 12
Leadership
Successful Project Management
Process based PM in CVDS 3.0
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Start – Kick-off
10
9
8
7a
7
6
Requirement/Implementation specification process 1)
5
4
3
2
End of market launch
Product reliability
1
0
Harmonized release logic Tooling process
Frontloading
Integrated
100 % customer Conclusion of Start of ready parts/ development Production Start work (SOP) production tests
Sign off process (on/ off highway)
Synchronization of various projects (e.g. After treatment system to vehicle and to engine) Revised description of target and details for all roles in development
Methods in Project Management
CVDS 3.0
Updated
Start
S 1)
Updated
Project scope and working directions
10
Updated
Project req. spec
9
Updated
Updated
Develop. Component suppliers req. specs pre-selected
8
Standard Requirement Specification = STARS-Project
7a
B-Sample available, Project implem. spec
7
Updated
C-Sample available
6
Updated
Finalization of LL-tool Finalization Design release
5
4
100% customer ready parts, start of prod. tests
3
SOP
2
Market launch Product completed reliability
1
0
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1. Overview
Series Principle Concept development Availability BTool Outline feasibility/ feasibility/ feasibility/ Sample/ Availability Crelease Specification Framework Functional Development 100 % final Sample for LL specification specification suppliers are specifications determined
S
CVDS 2.0
Changes in the process model lead to the adoption of new QG definitions in CVDS 3.0
2.Product Creation Process (P)
2. P
1. Overview
1. Overview 1.
6
2. Product creation process (P) 2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/32 roles
9
2.2.
Quality Gates for truck and aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks over time
36
2.4.
Main topics and details
69
Planning, assessment, reporting, steering
87
3. Methods 3.1 – 3.4
3. Methods
Goals and principles of CVDS 3.0
s
99
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1. Overview
2.Product Creation Process (P)
10
Module 1: Concept
12
Module 2: Specification
13
Module 3: A–Sample
14
Module 4: B–Sample
15
Module 5: C–Sample
16
Module 6: D–Sample
17
Module 7: Series suppliers for C-Sample
18
Module 8: Series suppliers
19
Module 9: Production planning
20
Module 10: Production Ramp-Up
21
3. Methods
Frame Schedule and standard project organization
2. P
2.1. Product Creation Process (P): Frame Schedule and its modules
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Overview about P for truck and aggregate projects Project scope and Start working directions
S
10
Project req. spec Concept selection
QFD
Component req. specs
9
8
Develop. suppliers Project implem. spec pre-selected B-samples available
7a
7
Finalization of LL-tools release
6
100% parts „V“
Working directions
C-sample available
5
Finalization design
100% customer ready parts
SOP
4
3
2
Release of comp. with required confirmation
100% parts „E“
Finalization development
Market lauch Product compl. reliability
1
0
100% parts „_“
100% parts „P“
Market req. Techn. ideas
Preselection
Strategy for develop. depth and general make-or-buy
Prepare and define product- and production concepts
1. Concept
Plant location decision
Product req.spec
2. P
Release of comp. without required confirmation
Make or buy decision
Engineering Release of entire product
Product impl.spec
Component impl. Spec Sys + Component (inhouse+ext. development req. specs Develop. contracts Concept competitions Production Production. Production concept req. specs impl.specs Project Project req. specs impl.specs
2.Specification
Concept A
Design
Analysis Simulation Analysis Manufacturability A-sample Drawing release
Design B-sample components
Components Test Entire product
IQG 0
Component Test Test A-sample
5. C-samples
„V“ Release B
„E“
Build-up
Confirm final design status „P“
Release C
Release D (Finalize design)
Finalization “_“ development work Analyze results of D1 comp. testing
Component test
Test B-samples
Build-up Accelerated test
Test C-sample entire product
Selected P-releases
7. Series suppliers for C-samples (only selected parts)
„P“ Assign series supplier with series tools „E“
100% product release (ISIR)
6. D-samples
Confirm CD
Analysis C-samples
Component test
4. B-samples
Delivery date of first parts from series production tool (D1)
Only vehicles
Optimize BC
Analysis B-samples
3. A-samples
Styling Freeze
Data-control -model
Select series supplier with prototype tools
Verific. Build-up Certific.run Product release inhouse parts
8. Series suppliers Request for quote… …order placement Tool manufacturing Series supplier
Product release purchased parts Optimization
Requirement specs for manufacturing equipment
10. Production Ramp-up
Request for quotes… …Order placement
9. Production planning
Confirmation run D-samples
Track manufacturing equipment
Ensure parts availability for production tests Optimization and finalization
Installation Start-up approval
Final approval + handover to series production Production Ramp-up tests 1-3
Series production
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Responsibilities and reference project organization is derived into 11 subprojects and 32 roles
L TL TM TS TW
1) 3)
Project leader Logistics Integration Material Handling Engineering (MHE) Production Programming & scheduling PPS ISC: International Logistics
TI
IBL: Inbound Logistics
TC
LCM: Launch & Change
TP
PMC: Prod. Mat. Control
TO
OBL: Outbound Logistics
Abbreviation Roles
Abbreviation Roles
Engineering 3)
SQ
Supplier Management
EL
QL
Quality
EI
Integration
QM
Quality Manufacturing
ED
Design
QE
Quality Engineering
EV
Documentation
ML
Manufacturing 3)
EP
Proving/ Testing (entire product, component)
EC
Calculation/ Simulation
EE
Electrics/ Electronics
ES
Styling1)
Prototype build-up
ET
Thermodynamics 2)
PL PE
Purchasing Equipment
PP
Purchasing Parts
MF
Facility Planning
ME
Manufacturing Engineering
MM
MP
Manufacturing in the launch
AS
After Sales
Manufacturing – supply of prototype parts Cost Planning
SM
Sales
FC
Finance & Controlling
MS
Only for truck projects 2) Only for aggregate projects For ML, EL, PL no specific sub-project lead processes are defined, only summary of linked sub-roles
Purchasing 3)
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2. P
Abbreviation Roles
Module 1: Concept Project scope and working directions
Project req. spec
Component req. specs
Develop. suppliers pre-selected
9
8
7a
Concept selection Konzeptauswahl
S
10
7
Target positioning and working directions
SM
Compilation technical ideas
ED L
Define project scope and working directions
FC
Set financial target guidelines I to V ED Pre-select technical ideas Investigate concept feasibility entire product Development depth strategy
EI
2. P
Project implem. spec, B-samples available
EI
Description of production network alternatives
MF
ME
Make-or-buy strategy
Define product- und production concept (through Design to Target (DtT) Workshops) Define product- und production concept (through Design to Target (DtT) Workshops)
L
Concept selection Development-depth decision
L
Plant location decision
L
L
Definition
Make-or-buy decision
This module contains all measures and activities necessary for a successful start of the development process and for conceptual decisions. Conversion of customer and market requirements into project goals and working packages. L FC
Project leader Finance & Controlling
EI ED
Integration Design
SM ME
Sales Manufacturing Engineering
Cost Planning
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Module 2: Specification
EI ME FC L L L ED ED
Component req. specs
Develop. suppliers pre-selected
Project implem. spec, B-samples available,
9
8
7a
7
Functional requirement spec entire product contribution to project requirement specification for production planning Project Business Case I to III Project requirement specification Set-up project team for realization phase L Project hand-over Preparation of technical spec for system requirement specs. Technical specifications for component requirement specs.
Project Implementation Spec
2. P
Concept selection
Project req. spec
development supplier offer implementation specs
ED
Decision on styling Concept competitions - LOI
ES PP
Confirm req. spec content for in-house development implem. spec compilation by ext. dev. suppliers
ED ED
Development contracts
PP
Detailing of production concept Finalization of prod. concept ME (for implem. specs)
ME
Definition Within this module all results from the concept phase are documented as requirement and implementation specifications. Contracts with development suppliers are signed. EI ED
Integration Design
PP FC
Purchasing Parts Finance & Controlling
L ES
Project leader Styling
L
ME
Manufacturing Engineering
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Module 3: A-samples Project scope and working directions
Component req. specs
9
8
Concept selection
S
10 ED
Project req. spec
Integrate advanced engineering Concept design A-sample components
ED
2. P
EV
Documentation for Simulation A EC
Simulation of components design status A
MP
Review manufacturability design status A Documentation/ Drawing release A-sample
EV
Procurement and delivery of parts & tools A sample
MS
Test A-sample
EP MP
Install design status A-components into mule EP
Test A-sample aggregate carrier
Definition This module assures innovative components and s the selection of competing concepts within the product projects. Synchronization for advanced engineering. A-samples have limited functionality, ready for test bench. ED EV
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
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Module 4: B-samples Component req. specs
Develop. suppliers pre-selected
Project implem. spec, B-samples available,
C-Sample available
9
8
7a
7
6
Design B-sample
ED EV
Documentation for Simulation B Simulation of components design status B
EC
Prototypes for component implem. specs
MP
Review manufacturability design status B
MP
Update design status B Drawing release ‚V‘ B-sample 1)
ED EV
Procurement and delivery of parts & tools B sample
MS
Test B-sample components
EP
Build-up entire-product design status B
MP EP
Install measuring technology (B-sample) EP
Test B-entire-product
Definition This module assures the functionality of components and the entire product. Testing is realized on test bench or in the entire product. Evaluation, whether reliability requirements are provable within the following C-samples. ED EV
1)
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
For Non-MB projects refer to release logic p.77
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
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2. P
Concept selection
Project req. spec
Module 5: C-samples Develop. suppliers pre-selected
Project implem. spec, B-samples available,
C-Sample available
Finalization of LL-tool release
Finalization design
7a
7
6
5
4
Optimize components design status B to design status C
ED EV
Documentation for Simulation C Simulation of components design status C
EC
Review manufacturability design status C
MP
Completion design status C (close to series)
2. P
ED
Drawing release ‚E‘ C-sample 1)
EV MS EP
Procurement and delivery of parts & tools C sample Test C-sample Build-up entire-product design status C
MP EP
Test C-entire-product
Install measuring technology EP
Definition All activities within this module are focused on the assessment of the life-span and reliability of the components and the entire product. C-samples product characteristics mainly fulfill expectations for series production. ED EV
1)
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
For Non-MB projects refer to release logic p.77
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
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Module 6: D-samples C-Sample available
7
Finalization of LL-tool release
Finalization design
5
4
6
100% customer ready parts, start of prod. tests
3
SOP
Market Launch compl.
2
1
Product reliability
0
Complete 1:1 model - styling freeze ES Final Class-A data Data control model ED Confirm design status D ED Write RfQ documents for future series supplier with development content EV Documentation for Simulation D EI Engineering Release of entire product Simulation design status D EC EP Confirmation D-Components Review manufacturability design status D MP
ES
Finalization design (series)
ED
Drawing release ‚P‘ (series, ordering tools)3)
Finalization development
ED EV
Release of components for pre-production test
Finalization documentation ‚_‘ 3)
EV ED
EV
Documentation for pre-production tests
Release configuration codes ‚V‘/ (preliminary)
EV
EV
Confirm configuration codes 2)
MM Ensure parts availability for pre-tryout („BANF“) TP Build-up entire product in pre-production tests Manufacture D-sample parts ME Confirmation run D-sample entire product EP
Product release (in house parts) QM Customer driving tests 1)
Definition
Certification
EI AS
All activities necessary to achieve series feasibility of the components are described within this module. The actual product has been certified with all components and can be used without any restrictions (released). AS ES ED 1)
After Sales Styling Design
In Japan/India later than SOP
EC EV MP 2)
Calculation/ Simulation Documentation Prototype build-up
Blank Code/Final Code for Non-MB projects
QM ME MM 3)
Quality Manufacturing Manufacturing Engineering Manufacturing in the launch
EI TP EP
Integration PMC: Prod. Mat. Control Proving/ Testing (entire product, components)
For Non-MB projects refer to release logic p.77
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2. P
Project implem. spec, B-samples available,
Module 7: Series suppliers for C-samples (only selected parts) Develop. suppliers pre-selected
Project implem. spec, B-samples available,
7a
7
C-Sample available
6 Design components design status C=series 1)
ED
RfQ and assignment of future C=series suppliers with development content (only selected parts)
PP
Drawing release ‚P‘ for C=Series 3)
EV
RFQ and assignment suppliers C=Series
PP
2. P
Track C sample prototype tools 2) Track tool manufacturing (in-house parts) Prepare + select C=series suppliers (prototype tools)
ME
PP
Track C sample prototype tools 2)
Component test C-sample
EP
Definition This module is focusing on those C-sample components, that should be available from series suppliers for C-sample testing. The components can be produced by prototype tools and in special cases also by series tools. ED EV 1) 2)
Design Documentation
PP
Purchasing Parts Cost planning
ME EP
Manufacturing Engineering Proving/ Testing (entire product, components)
3) For Non-MB projects refer to release logic p.77 C=Series: same tools for C-samples and series Responsibility is shared between SQ and specifically for different organization units
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Module 8: Series suppliers C-Sample available
Finalization of LL-tool release
5
6
100% customer ready parts, start of prod. tests
Finalization design
4
3
RfQ and assignment of future series suppliers with development content (only selected parts) 1) RfQ and assignment (incl. tools)
PP
Series purchasing contracts
PP
Track tool manufacturing series suppliers 2) D1-components
Optimization of series production tools at series supplier 2)
D2-Components Series preparation at series supplier
SQ
Product release (purchased parts)
SQ
Definition This module includes the activities required to contract series suppliers for series production parts and tools. PP
Purchasing parts
1) Documents 2)
Cost planning
SQ
Supplier management
for RfQs from module D-sample Responsibility is shared between SQ and specifically for different organization units
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2. P
PP
Module 9: Production planning Project implem. spec, B-samples available,
C-Sample available
7
6
ME
Finalization of LL-tool release
100% customer ready parts, start of prod. tests
Finalization design
5
4
3
Description and planning of manufacturing equipment Req. specs for manufacturing equipment
ME
PE
Evaluation of implem. specs for manufacturing equipment
ME
2. P
RfQ manufacturing equipment
Order placement manufacturing equipment Track manufacturing equipment
PE
Start PT1
ME
Optimization and finalization of manufacturing equipment Installation, start-up, approval of manufacturing equipment
ME
ME
Definition This module includes the activities required to plan, order and ensure the availability of machines and equipment for the inhouse production. ME
Manufacturing Engineering
PE
Purchasing parts
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Module 10: Production ramp-up Finalization design
100% customer ready parts, start of prod. tests
4
3
SOP
Market Launch compl.
Product reliability
2
1
0
Finalization of sales documentation SM
Vehicle configuration for production tests SM Production configuration series/ option Initialize sales order process
SM
Final approval and handover to series production Ensure manufacturability (Complain management.)
ME
2. P
SM
MP
Ensure parts availability for production tests
TP
MM
Production test 1 MM Production test 2 MM Production test 3 Production ramp-up
MM
Series production
MM
Process release (purchased parts)
SQ
Project closure report
L
Definition This module includes the activities required to plan the production ramp-up, to test the production (process flow, quality, tact) and to actual facilitate the market supply within series production. SM MM
Sales Manufacturing in the launch
ME L
Manufacturing Engineering Project leader
SQ TP
Supplier management PMC: Prod. Mat. Control
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1.
Overview of quality gate 10 to 0
23
2.
Detailed description on main content of each quality gate
24
2. P
Page
3. Methods
2.2 Quality Gates for truck and aggregate projects (definition, content, responsibility)
1. Overview
2.Product Creation Process (P)
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The 12 Quality Gates for truck and aggregate projects following CVDS 3.0 10
9
8
7a
Product finding and definition
7
6
5
4
3
2
1
0
Production Ramp-Up Series production
Product development
Define project scope and working directions Project and concept decision (project requirement specification)
2. P
100% Component requirement specifications Development suppliers are pre-selected Project implementation specification, availability B-sample Availability C-sample Finalization tool release for long lead, C-sample pre-tested Finalization design 100 % customer ready parts / start production tests Start of production (SOP) Market launch completed Product reliability Daimler Trucks | 23
Quality Gate 10: Project scope and working directions 10
9
8
7a
2. P
Definition The project scope is defined. Transparent and measurable working directions for the project are defined. Their definition is based on previous market analysis, competition analysis and predecessors analysis, combined with the strategic requirements of the corporation and adapted to the legal project requirements.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • •
• • • •
Project scope and working directions of all line functions are documented. They are presented to the customer (e.g. PEC) in order for him to take a decision. All necessary resources up to QG9 are available (planning and release of the resources occurs within the FPL framework). Project organization up to QG9 is active since project start. Market analysis and product placement are done ( incl. customer requirements, competitors positioning, required product variations, return and quantitative concept). Gathering of technical ideas starts (Finalization after QG10), potential innovations from pre-development might be integrated at this point. Legal requirements are determined (L and Ex, Qx, SM). Working directions of quality management are defined. Top-Down-Requirements regarding economic efficiency (guidelines) are determined: Working directions concerning profitability, unit costs and resource requirements. Initiation of data collection for the development of product and production concepts (Finalization after QG10) : Competitors components study, data for target cost calculation incl. unit costs of the predecessor's top-parts (if available). Basic costs for predecessor's parts have been handed over to . Basic version of the production network is described. Working directions of the production are available (e.g. optional eHPU Top-Down-Requirements) Working directions of after sales are defined (e.g. maintenance intervals).
L L SM Ex L QL FC
PP MF ME AS
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Quality Gate 9: Project requirement spec (project- and concept decision) 9
8
7a
Definition In interdisciplinary teams a technical concept, which realizes the QG10 working directions in the best possible way, has been developed. (Design to Target) The technical feasibility of the product concept, with respect to development (geometry, technique, innovation), production (manufacturability, innovation) and its service capability, has been verified by Ex/Mx . Based on the economic efficiency calculation, project targets, regarding profitability, unit costs and resource requirements, are defined. All sub-projects define their Project Requirement Specifications. Project Requirement Specifications, incl. the schedule framework, are handed over to the series project leader.
7
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • • •
Project requirement specification, incl. project targets / demands of all parts and risk analysis, is available and has been handed out to the series project leader. Initiation of series project after QG9: Series project leader is nominated, project structure and schedule framework, incl. ramp-up strategy, are done. Ex/Mx confirm the product concept (range of development/ innovation, product properties, range of product variety, concept complexity) to be technically feasible and the concept is documented within the product requirement specification. Development depth is defined. Production and logistics strategy (basic manufacturing concept, strategy for the development depth, requirements concerning a production-appropriate product design) are worked out. Pre-selection of the production network is done. QG9´s economic efficiency calculation is based on the most promising configuration. Depending on the project scope, cross-functional Design-to-Target workshops have been organized and completed. Their purpose is to find a concept decision. This concept is documented on component sheets. The economic efficiency calculation is done as new target for the series project ( incl. targets regarding profitability, unit costs and consolidated resource demands). Quality and environmental targets are defined. Selection analysis for D-FMEA has been finalized. A concept for returns, quantitative concept and detailed product requirements (incl. a list of configurations for the reference-vehicles) are available. Purchase strategy, including its contribution to the project profitability, is set up. (Influence of the market environment) After sales strategy, including its contribution to the project profitability, is worked out.
L L Ex
Ex Mx Mx FC Qx SM PP AS
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2. P
10
Quality Gate 8: 100% component requirement specifications 10
9
8
7a
2. P
Definition Based on the Project Specification Book and the respective component sheets component sheets, development depth is decided. Detailed requirement specifications for components are worked out in their respective form, depending internal and external development range (Component Requirement Specification). Regarding the external development range, concept competition starts.
7
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • •
Depth of development is decided. Planning of series suppliers for the C-sample, „series suppliers with development scope“, within the component / purchasing schedule. System Component Requirement Specifications and missing Component Requirement Specifications are ready. They are being completed by different contributions of all sub-projects, including estimates on the costs of logistics and driving forces of variation. Start of concept competitions Based on the project requirement specification, design of the B-sample starts. A first factory layout is defined. Market introduction and LCM concepts are further detailed. System FMEA for the product has been carried out. Generation of the production concept initializes. Initiation of risk analysis for development supplier's competition, including component risks. Based on the component requirement specification, target costs are detailed on a final level.
L L All
PP ED MF SM QE ME SQ
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Quality Gate 7a: Series development feasibility / development suppliers are pre-selected (LOI) 9
8
7a
Definition There are development suppliers offers for all different levels of quoting requests. Based on this development suppliers are selected by LOI. A first completely documented design status B is available and ready for simulation ( internal and external development). Series development feasibility is proven– the budget to build up functional samples (B-sample) is approved.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • • •
Concept competition completed, offers have been received. Offer evaluation for development suppliers selection is being completed by also considering the subprojects point of view. Development pre-contracts (LOI) are finalized. Component schedule and purchasing schedule are updated. C-Sample components, manufactured by series and prototype tools, are further detailed. Estimations of the HR potential for production are made. Early comparison of targeted per unit costs and the real per unit costs for the entire product. The projects profitability is affirmed. Design status for B components is completed, documented and ready for calculation Based on the merging model (combination of 1:4 models design elements) a styling decision is made. Software for B-sample is implemented and integrated. Test planning has started. Preliminary project implementation specification. Application to release the B-sample purchasing budget
PP All PP L MM FC Ex ES EE EP L
Daimler Trucks | 27
2. P
10
Quality Gate 7: Project implementation specification, availability B-sample 10
9
8
7a
2. P
Definition Implementation specifications of all development ranges fulfill the requirement specification (internal and external developments) and are approved. Design status B is fully documented, analyzed (calculation and producibility analysis) therefore represents the implementation specifications. External development ranges are assigned and contracted (=100% implementation specification for external development). Functional validation starts on component level. Detailed implementation concepts for all subprojects confirm all requirements of the project requirement specification. The implementation specification for the entire project and the implementation concepts are aggregated into the project implementation. Project budget gets approved and the execution of the entire project is authorize.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • •
• • • •
Project Implementation Specification is completed by the Implementation Specification of the entire product and different contributions from each sub-project. Decision over localization and depth of production is made. Requirement Specifications for the different external development ranges are created by the development suppliers. Development contracts are signed. Design-FMEA. Initial status is worked out before a drawing release for the B-Sample is given. All calculations necessary are completed for design status B. Drawing release for B-Sample is given and components have been acquired. B-Sample components are pretested and an assembled B-Sample is ready. The entire product can be tested (function) and software is available. Procurement schedule for internally manufactured C-Sample tools is set up. Production concept is determined up to workstation level. Demand for Production Equipment is described and planned within a time scheduled. Logistics' concept is worked out (contribution to project implementation spec). Comparison between targeted and real costs per unit for the entire product. The project's economic efficiency, based on the Project Implementation Specification and a finalized project budget, is confirmed and approved.
L L ED PP QE EC Ex/ Mx L ME TL FC
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Quality Gate 6: Availability C-sample 9
8
7a
Definition Based on the Projects final specification, B-samples are tested relating functionality and integration according the entire product. The from B-sample tests ensure the optimization from design status B to C. This optimized design status is calculated and analyzed for manufacturability. It results in a released design status C for durability testing (near series design status). Components are pre-tested, the CSample entire product is build up, and is available for testing.
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • • • •
*
7
B-Sample testing is completed ( components, entire product) Initial confirmation of fulfillment of Q-targets of B- Sample and C-Components. Components´ and purchasing schedule: - For suppliers for the C-Sample (prototype tools) is set up. - Reachability of evaluation dates, before the start of production, is assured. (backwards scheduling of the part releases „P“) * All design calculations are completed for design status C. C-sample drawing release is available for procurement of components out of prototype tools respective for selected components with C = series tools Manufacturing of the C-sample tools has been accompanied C-sample components are procured and pre-tested C-sample is built-up and ready to the entire product testing Requirement Specifications for production equipment are available. Detailed planning of methods and processes for supplier and material flow controls completed Marketing Confirmation: Price and quantity requirements and product positioning are confirmed Service check with B-sample is finalized, preliminary damage codes are generated Building applications have been placed and building permissions have been granted for all necessary facility constructions.
For Non-MB projects refer to release logic p.77c
EP QE L
EC EV Ex MP ME TP SM AS MF
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2. P
10
Quality Gate 5: Finalization tool release for long lead, C-sample pre-tested 10
9
8
7a
2. P
Definition Based on the first results of C-sample entire product testing (durability, rough road, reliability), the design status C is confirmed as a series design status D and released for long lead tools and production equipment. Start of the inquiry process for series suppliers including tools (external production) and production equipment and tools (inhouse production). At this Gate the critical path moves for the release components from the development to the procurement of production equipment and to the assignment of series suppliers. In the case of aggregate projects this gate serves as synchronization point to the target vehicle (pre- tested C-sample aggregate for prototype vehicles delivery date C-sample at Gate 6).
7
6
5
4
3
2
1
0
Overview of main contents • •
• • • • •
C-Samples pre-testing of the entire product is completed (rough road test, overload test usually summer and winter testing) According parts with long lead tools: - D-sample design status has been verified by simulation and manufacturability analysis, - Q-objectives and FMEA measures and validated - parts variety, planning and calculation of series - production tools are proofed. Component and procurement schedule: Preparation for contracting of series suppliers and production equipment suppliers is finalized Planning of production workflow has been updated based on the experience from the C-sample built-up. Risk analysis for production planning: Process FMEA initial position is available The Project efficiency is ensured for the beginning of the series releases. All long lead series tools are fully documented and released.
EP All
L ME QM FC Ex
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Quality Gate 4: Finalization design 9
8
7a
Definition The vehicle durability feasibility is proven by a successful completion of the C-sample's entire product tests (endurance test). Design work is completed: According to its lead time, the drawings for design status “series” are released for all machines and tools in order to start the order placements – All Requests for Quotation, for production equipment, are available. Series and production equipment suppliers are hired, according to the component and procurement schedules.
*
7
6
5
4
3
2
1
0
Overview of main contents •
Sufficient C-sample testing entire product confirms the reliability and durability requirements
Results from reliability testing, the design release for all parts. DMU-integration is successfully completed. • For all parts, considering their tool lead time: - Simulation and manufacturability analysis have verified D-sample design status, - Q-objectives are proofed and FMEA measures are validated. - Variety of parts, planning and calculation of series production tools is confirmed. • Design status for series is available. Tool release for all tools is completed (100% “P”)* •
Assignment of series suppliers and production equipment initiated. Product documentation and production program are included into the logistic systems. • Process and equipment spec of logistics is worked out (and deemed to be and of detail planning and basis for implementation) • Finalization of the Requirement Specification for logistic equipment and service suppliers. • Code-release „V“ (preliminary) is started. • •
For Non-MB projects refer to release logic p.77
Ex Qx Ex/ Qx All
ED/ EV Px Tx TL Tx ED
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2. P
10
Quality Gate 3: 100 % customer ready parts / start production tests 10
9
8
7a
Definition
2. P
All parts and their series tools are tested and sample part evaluation is finished (100% ISIR (Initial sample inspection report) released for inhouse and purchased parts). Drawings design status “Series“ confirmed – unlimited release of parts for production and after sales (stocking of parts). The production equipment is completely installed, approved, and ready for the start of the production tests. A D-sample was built-up as entire product and the certification has started.
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • • • • • •
*
7
All parts, tools and production equipment are assigned, all purchasing contracts are signed All parts are produced with series tooling and shortly tested The production equipment and tools are completely installed, acceptance and start-up of the production equipment enables the start of tryouts. Progress of process implementation secures the tryouts D-samples are built-up (pre-tryout) Certification has started All in-house and supplied parts are evaluated (product release, ISIR/PPAP) Development is completed and entire product development release is available “_” release for the parts used in production and after sales (stocking of parts for tryouts and start of series production)*. All codes have been ‘_’ (final) released. Prices for vehicles and product configurations series/ option are defined. Finalization of marketing master plan, Products for exhibition purposes are available D-Sample confirmation tests have started. Sales documentation is finalized and approved for PT1
For Non-MB projects refer to release logic p.77
Px All ME Tx MM EI QM/ SQ Ex Ex Ex SM SM EP SM
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Quality Gate 2: Start of production (SOP) 9
8
7a
Definition Production tests (tryouts) confirm the capability of the plant to produce products, which are customer ready, without any need for reworks (assembly line completed, quality and tact time). Product and process are released. Homologation for target markets (SOP) is completed. Serviceability for primary target markets is assured. All requirements for the production ramp-up (SOP) are fulfilled. Series production is ready to start.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • •
Production tests are successfully completed: Production workflow verified, product and process release (product audit of entire product) Logistic processes are completely implemented Series-order-process established Finalization of series preparation at suppliers Staff training for series production finished ment for all planned media is prepared and relevant marketing information (commercial and technical) is distributed Homologation is completed and available for target markets (SOP) Serviceability for first target markets (SOP) is assured Production ramp-up is secured Project efficiency is confirmed according to the Project Final Specification, all key figures meet the project targets
Mx/ QM Tx SM SQ MM SM EI AS All FC
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2. P
10
Quality Gate 1: End of market launch 10
9
8
7a
2. P
Definition During market launch all Marketing communication measures for the new product are carried out. From SOP on, vehicles are delivered to dealers and selected customers. According to the target markets, serviceability is assured. Production reaches its full capacity rate for the entire product variety. Hand-over to series production is completed.
7
6
5
4
3
2
1
0
Overview of main contents Production reached ridge line during ramp-up. Final acceptance and approval of the production equipment is finished. • Sales documentation is completed and distributed within the sales network. Sales staff training is completed. • For all target markets spare parts availability during market launch is secured. • Series process is verified (entire variety) and continuous improvement process (KAIZEN) is started. • •
Unit cost calculations (based on the updated data of series parts) are finalized and comply with targets. • Customer driving tests have been evaluated. • Hand-over to line organization is completed. •
MM ME SM AS ME/ MM FC AS L
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Quality Gate 0: Product reliability 9
8
7a
Definition The product reliability is analyzed and evaluated. Measurements to optimize the product are determined. Commitments documented in the project specification and respectively specifications of all subprojects are verified within the final project report. The project leader and the project team are discharged.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • •
All final acceptances of equipment have been carried out with positive results. Confirmation run of D-sample entire product to prove reliability is completed. Profitability of the entire product is calculated according to F&C standards Lessons Learned are documented. Final quality report is prepared: Long term capability of production processes is proofed. Product audit within series process is accomplished. Based on the final consolidated economical evaluation the project economic efficiency is confirmed. All key figures meet the projects targets. Final project report is completed.
ME Ex FC All QL/ QM FC L
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2. P
10
1. Overview
2. Product creation process (P)
2.3 Main content/ roles and their tasks over time 32 Roles – one page per role
37
3. Methods
2. P
1.
Page
Daimler Trucks | 36
Main role content of Project Leader (L) Main topics
FPL Concept and specification
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Working directions QFD Concept selection Legal requirements Align project org. with concept decision + handover to project QG10 leader chapters Proj. implementation specs Proj. requirement specs
Handover to series Final project report
req. specs
Changemanagement
implem. specs B-sample
C-sample
Invest
Releases
C=series tools payments
Assign development suppliers for development Location/ Integration
Time schedules
Make or buy
Start Time sensitive Matrix components
Invest series tools + manufac. equip. Internal contracts
Development depth Strategy Decision Strategy
D-sample
Legal framework
Series
Final payments for manufacturing equipment for supply
Location Decision
Series suppl. for for C-sample B-sample
Series for suppl. w/ C-sample dev. costs
Ensuring Ensuring tool awarding lead time phase
Further topics: Project synchronization (aggregate – vehicle)
Component/procurement scheduling PM
Detailing Planning/ Working Set-up Project order
Stabilization PM
Verification project order
Project Closing Project steering
Daimler Trucks | 37
2. P
Analysis of project complexity + initiation of risk management
Main role content of Logistics Integration (TL) Main topics
S
10
Concept selection
Logistic Strategy
Frontloading
9
8
7a
7
Logistic Concept
6
5
4
Detailed Planning
3
2
1
Implementation
Contrib. to location decision Predecessor analysis
2. P
Strategy
Logistics costs
Assessment of supplier quotes
Logistics costs
Specification process
of development suppliers
Costs for creation of scenarios
Costs & funding for business case
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=series suppliers
Target costs logistics
Contrib. to Project implementation spec
of series suppliers
Continuous reporting target- vs. EA-costs
Process & equipment spec
Operation manuals
Daimler Trucks | 38
0
Main role content of MHE: Material handling engineering (TM)
Location
S
10
Concept selection
9
8
Logistic Strategy Contrib. to location decision
Material flow
Selection of basic delivery modes
7a
7
6
Logistic Concept
5
4
Detailed Planning
Concept of material provision and delivery modes
3
2
1
Implementation
Production tests
Detailed planning of material flow processes
SOP
Implementation of material flow processes Carrier/ container Conception
PTs
Determination
Planning
SOP
Provision Final coordination of packaging with suppliers
Carrier & equipment
Planning of logistics equipment Req. specs for logistics equipment Procurement of logistics equipment Buildup, startup, approval
Area
Assessment of supplier quotes
Specification process
0
Requirements for area (Business case)
Verification & rough layout
Detailed planning
Area allocation plan Area allocation
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
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2. PEP
Main topics
Main role content of Production programming & scheduling (TS) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept
4
Detailed Planning
Definition of methods
Process Planning & Implementation
5
3
2
1
Implementation
Detailed planning
Coordination of planning restrictions Analysis Specification
Implementation & Verification
Securing IT
2. PEP
Calculation of parts demand Initialization / Implementation
Production program
Creation of production program on level „model range“ Creation of production program on level configured products e.g. model, code
Parts demand
for Production Tests for Start of Production
Specification process
Contrib. to Project requirement spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
Daimler Trucks | 40
0
Main role content of ISC: International logistics (TW) Main topics
S
10
Concept selection
9
Logistic Strategy
8
7a
7
6
Logistic Concept
5
4
Detailed Planning
3
2
1
0
Implementation
Definition of basic supply chain scenarios Concepts & Processes for Internat. supply
Assessment of supplier quotes
Specification process
Determination of internat. supply concepts
Rough concept internat. supply
Detailed planning
Verification
1st Shipment PTs Series EDI ready Implementation of Series processes
Data collection Requirement specs for service providers internat. supply
Coordination of IT-Concepts Inquiry of new transportation concepts & relations
Contracting
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
Daimler Trucks | 41
2. PEP
Contrib. to Location location decision planning
Main role content of Inbound logistics (TI) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept
5
4
Detailed Planning
3
2
1
Implementation
2. PEP
Contrib. to Location location decision planning
Definition of basic transportation concepts Concepts & processes for Transportation
Determination of transportation concepts
Detailed Planning of transportation concepts
Production tests Series Implementation of series processes
Inquiry of new transportation concepts & relations Requirement specs for service providers Contracting
Assessment of supplier quotes
Specification process
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
Daimler Trucks | 42
0
Main role content of LCM: Launch & Change (TC) Main topics
S
10
Concept selection
Logistic Strategy Process Planning & Implemen -tation
9
8
7a
7
6
Logistic Concept Definition of methods
5
4
Detailed Planning
2
1
0
Implementation Initialization / Implementation
Detailed planning
Analysis
3
Specification
Prod.docs input
Implementation
Consistency testing D-Sample 18 15 12 9 6
Documentation
Update (based on ‚_‘) Check for crit. types Production tests SOP
Scheduling & Ramp up planning
Specification process
Scheduling
For complete product range
Contrib. to Project requirement spec
Ramp up planning
Contrib. to Project implementation spec
Update
Contrib. to Process & equipment spec
Detailing Ramp up scenario
Operation manuals
Daimler Trucks | 43
2. PEP
Securing IT
Main role content of PMC: Prod. Mat. Control (TP) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept Concepts for material flow control
5
4
Detailed Planning
3
2
1
Implementation
Detailed planning of methods/processes
Production tests SOP
Material Flow Control
Implementation of internal material flow control Securing IT
2. PEP
Detailed planning of methods/processes for supplier control
Implementation of Processes for supplier control Verification of inventory planning for purchased parts (required storage area)
Supplier Control
Parts availability for pre-tryout (BANF) Call off orders for ISIR parts Parts availability production tests Parts availability for Ramp-Up
Specification process
Contrib. to Project requirement spec
Contrib. to component req. spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
Daimler Trucks | 44
0
Main role content of OBL: Outbound logistics (TO) S
10
Concept selection
9
Logistic Strategy Location planning
8
7a
7
Logistic Concept
6
5
4
Detailed Planning
3
2
1
0
Implementation
Contrib. to location decision Definition of basic transportation concepts
Determination of transportation concepts
Detailed planning for particular markets
Production tests Series Implementation of Series processes
Inquiry of new transportation concepts & relations Concepts & processes for Transportation
Space requirements for shipping Estimation Detailed planning Virtual loading test
Physical loading test Requirement specs for service providers Contracting
Specification process
Contrib. to Project requirement spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
Daimler Trucks | 45
2. PEP
Main topics
Main role content of After sales (AS) Main topics
Concept Specification
S
10
Concept selection
9
Proj. req. specs Concept AS working directions
8
7a
Contribution
7
6
5
4
3
2
1
0
Proj. implem. specs Ensuring part exclusiveness (for series awarding)
Verification in component implementation specs
Integration AS requirements in comp. requirement specs
2. P
Service Checks
Service Check secure serviceability work values/prices for W&P with A-sample
Diagnosis
Repair
Concept
Methods Customer driving tests *)
with B-Sample
Definition concept + req. repair center
with C-sample
Basic diagnosis Planning … Data input
with D-sample Development „Guided search for errors“
Deliver to repair center
Verification ‘flashing’
Market preparation and infor -mation
Plan: Training + service concepts
Marketing framework and training plan
Qualif. service network Preparation Service network Repair center info Document.
Procurement of spare parts
Verification AS Launch Check Standard languages Publication
Ramp-up process Concept spare parts (inhouse)
Spare part definition and bill of material
*) Customer driving tests in some countries (e.g. Japan + India) only permitted after SOP and with homologation
Check prod. reliability field
Basic availability Procurement
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Main role content of Sales (SM) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Market req. and competitors Product/ SM working directions product Quantities + revenues positioning Product portfolio Product positioning
Specification
Verification product req. change management product config.
Consolidation product req. product config.
Proj. req. specs
Contribution
Comp. req. specs
2. P
Product concept w/ series + options
Proj. implem. specs From development
Comp. implem. specs
created „V“ Code restrictions
Detailing of product requirements
Released „_“ Start of sales SOS
Concept Market launch
Ramp-up planning
Validation of quantities
Final.
Marketing framework
Vendor training
Events
Prepare media presentations Process and system adaptations
Market launch and lifecycle concept
Marketing documentation
Documentation prices Vehicle configuration Creation Centr.
Market Initialize sales order process
National Vehicle configurations Defines for prod.tests reasonability check national market launches
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Main role content of Supplier management (SQ) Main topics
Specification
S
10
Concept selection
9
Contrib. proj.req.specs
8
7a
7
6
5
4
3
2
1
Contrib. proj.implem.specs
for comp. req. specs Development suppliers B-Sample
2. P
C-Sample Control suppliers
18 15 12
9
6
D-Sample Series suppliers C=Series suppliers
for C=Series suppliers
Preparation for series
for series suppliers.
in preparing documents for RfQ Selection: suppliers Development suppliers.
C=series suppliers.
Series suppliers
Risk analysis Planning Prod. and processrelease
Evaluation C=Series tools
Product release *) Process release Long-term capability
*) ISIR / PPR: Product „green“ and process „min. yellow“
Daimler Trucks | 48
0
Main role content of Quality (QL) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Specification Q-Plan Concept phase
Working directions
Project targets from quality and legal req.
Quantification Confirm. for proj. implem. specs
Engineering release of entire product
Confirm consistent Q-objectives in comp. req. specs Concept validation
2. P
Specification for proj. req. specs
Setup time line for product audits
Finalize concept audit B-Sample
Confirm Q-objectives for entire product (based on comp.implem.specs)
100% finalization development („_“) 100% finalization design („P“)
Product and process release
Verification long-term capability
Release product development
Project audit for B-sample phase for C-sample phase Q-reports
for D-sample phase Final Q-report
*) carried out by plant quality dep. (QM-role)
Daimler Trucks | 49
Main role content of Quality manufacturing (QM) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Weak point analysis of predecessor Concept phase
Concept analysis evaluation Contrib. proj.req.specs
2. P
Q-Targets
Contrib. proj.implem.specs
Detailed QM plan for manufacturing
Detailing quality objectives for manufacturing
Implement into concept selection .First scope definition Process FMEA
Updating and activity monitoring Update of scope
Initial status
for C=series tools feasibility of safety relevant characteristics (for „P“-release) Q-control loops1..5
Planning Implementation Testing Verification efficiency Product audit
Implementation
C-Sample
PPR-inhouse parts
Pre-tryout
PPR-entire product 2) PPR: Product and process release entire product
Prod.test
Series
Product release1) Planning Process release
Verification process capability
1) ISIR / PPR: Product „green“ and process „min. yellow“
Capability of test devices.
Short-term
Long-term 2)
Planning
Impl.
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Main content of the role Quality Engineering (QE) Main topics
S
10
Conceptselection
9
8
7a
7
6
5
4
3
2
1
0
Analyze predecessor product
Reliability / Durability
Evaluate concepts from QE view Validate Quality for: engineering release design release of entire product
Input to QE targets Input proj. req. spec Define targets for entire product
Input proj. final impl. spec
Evaluate test planning B-sample
Monitoring endurance testing according to the test planning C-sample D-sample
Define targets for components Monitoring B-sample
W&P
Estimate W&P rates for concepts
ZEUS
Define targets for entire product
Issue Tracking
D-sample
Statement about reachability2)
Statement about sufficient confirmation2)
Statement about confirmation2)
B-sample
C-sample
D-sample
Notes to Simulation, Test planning, Design
Select components for FMEA FMEA
C-sample
W&P planning
Start FMEA comp. System-FMEA entire product
FMEA-updating and activity monitoring
Validate FMEA measures
Safety Identification Confirmation and Documentation relevant Parts (DS) 1) Coordinated by the QL role 2) Statements about Reliability, Durability and W&P serve as for Development
Daimler Trucks | 51
2. PEP
Concept Specification 1)
Main role content of Facility planning (MF) Main topics
S
10
Concept selection
9
8
Initial situation Description
7a
7
6
5
4
3
2
1
Conception
Production network
2. P
Pre-selection
Plant layout
Determination Plant location decision
Rough
Detailed Specification
Plan realization of constructions (contrib. implem.specs)
Realization
Time period for approval
Evaluation of basic information Concept planning Detailed planning Building application File the building application and approval Production planning
Application approved
Documents for RfQ RfQ phase Awarding Implementation planning
The entire part “Realization” has to be synchronized with the delivery of machinery and equipment
Approval Transfer of risks Ready for occupancy Implementation plan Realization
Remedy of defects Documentation
Date for building application: a) calculated by backward scheduling b) Time to permission + construction duration highly dependent on location
Daimler Trucks | 52
0
Main role content of Manufacturing Engineering (ME) S
10
Concept selection
9
8
Strategy
Make or buy
Concept
Detailing
7a
Decision
6
5
4
3
Release of investment
18 15 12
9
0
D1 D2 Manufacture D-sample parts
Assessment of quotes Track manufacturing Manufacturing equipment 2 C=Series TQG-1
Start-up Approval
TQG-0
Production work flow
Structure
Detailed planning
A-sample
Concept selection
B-sample
SOP Hand-over
Integration experiences Finalization C-Sample (Base for final Styling)
Interfaces (develop.)
1
6
Req. specs for manufacturing equipment
Production technologies Innovat. Verification of feasibility
Process laboratories
2
1
Contrib. proj. implem. specs.
Production alternatives
Production processes
7
2. P
Main topics
Verification
Start Kaizen
C-sample
Assessment of implem. specs of development
1 Make or buy decision is coordinated by „FC“ role
2 Special process: only applies for in house parts with C= series tools
TQG: Technology-QG: 1 Concept Suitability, 0 Applicable Technology
Daimler Trucks | 53
Main role content of Manufacturing in the launch (MM) Main topics
2. P
Concept
Planning staff requirements
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Requirements for staff
Evaluation of staff potential Update evaluation of staff potential
Planning of staff requirements Content and requirements for training concept
Recruit staff Recruit staff
Negotiation of company agreements
Training of staff
Staff ready
Staff for prototype manufacturing Staff training Staff training
Extended staff training (rotation and substitute) D1 D2 Manufacturing D-sample parts 1 2 3 Prod.tests
Daimler Trucks | 54
Main role content of Prototype build-up (MP)
Feasibility studies
S
10
Concept selection
9
8
For concept selection
7a
7
6
5
4
3
2
1
0
Produceability assessment of implem. specs
Securing comp. req. specs
design
Review manufacturability1)
18 15 12 9
6
Review manufacturability Verification of review manufacturability
2. P
Main topics
Ensure manufacturability in pre-tryout
Series preparation
Prod.tests Series Complain management Planning Build-up components
Prototype build-up
Production data for lines
Build-up entire product
Training of disseminators Testing parts from C=series tools
A-sample
B-sample
C-sample
Ramp-Up
D-sample Coordination & Complain management
PT1 PT2 PT3 Ramp-Up Series
1)
Review manufacturability: e.g. drivers cab (Interior/Exterior „Cubing“) chassis or aggregate first in digital form (DMU) afterwards physically (PMU) confirmed
Daimler Trucks | 55
Main role content of Supply of prototype parts (MS) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
2. P
Scheduling
Prepare procurement
Product documentation Procurement parts a. tools
Hand over to series
Hand over to series logistics
A-sample
B-sample
C-sample
Daimler Trucks | 56
0
Main role content of Cost planning () Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Specification target costs components Moderation product/production concept
D-Sample
Predecessor competitors (reference calculation) Top parts Pre-selection Component Assessment LOI implem.specs Target costs in comp.req.specs Assessment of quotes Contrib. proj. req. specs. Contribution proj.implem.specs
Plan Complexity Mgnt.
Cost assessment of changes C-Sample
B-Sample
Analysis
B-Sample
2. P
Product and productionconcepts (Design to Target) and cost calculation
Verification/ monitoring / confirmation C-Sample D-Sample
Organizational association has to be specified for the projects
Optimization of quotes Confirm. for proj.implem.specs
Funding
Target costs series tools for comp. req. specs
Tool cost optim./change assessment/ calculation B-sample C-sample D-sample 18 15 12 LOI
Tool Mgnt. 1)
Evaluate and confirm tool runtime
B-sample External development
6
Assess quotes from develop. suppl. Planning budget for series tools: Planed disposed funded Track tool manufacturing. 2)
1)
9
Comp. implem.specs
2)
C-sample
Within German aggregate plants „supplier management“ (role SQ) is responsible
D1 D2 Tool opti.2) Series
Daimler Trucks | 57
Main role content of Finance & Controlling (FC) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
Financial target guidelines
0
Final assessment of entire product in project closure report Validation prototype costs
Break down of working directions
B-sample Product- and production concepts
2. P
Definition of Target costs (Product)
1
C-sample
D-sample
Production Development location/ depth MoB-decision
Transition of project to series calculation
Financial evaluation/ Business case Determination and tracking of market and transfer prices Contribution for req. specs.
Project Profitability
Contribution for implem. specs.
Update project business case for each gate EA1)
Tracking target costs based on unit cost calculations for each gate EA1)
Cost approach (symbolic) Open project s
Confirmed in proj. req. specs for Budget Top down targets project order (Project) Funding for project req. specs
1)
Close project s
Finalized in proj. implem. specs for project implementation
Funding for B-sample and project implem. specs
EA = „Expected Actual“ that is comparison of status and target
Update funding and compare with periodical planning for each gate EA1) Funding for C-sample
until QG 0 Funding for series tools
Controlling and tracking of ramp-up costs
Daimler Trucks | 58
Main role content of Integration (EI) Main topics
S
10
Concept selection
9
8
Product req. specs
7
6
Confirm. req. specs= implem. specs
Comp. req. specs Specification
7a
Comp. implem. specs
Integration advance development Strategy Decision
5
4
3
2
1
0
Level of entire product
Integration of component level Engineering Release of entire product
Development depth
Concept analysis
Configuration entire product
Validation design
A-sample
B-sample
C-sample
2. P
Concept selection (DtT)
D-sample for pre-tryout
for prod. tests
Prev. to calculation 18 15 12
9
6
Prev. to procurement Design status on sample Characteristics Mgnt. 1)
Definition of requests Installation/ Build-up 1)
Analysis Assembly/ Body manufacturer
Validation Assembly/ Body manufacturer
Verification Assembly/ Body manufacturer Certification run
Define product characteristics
Homologation
Until „_“- release
B-sample
D-sample C-sample
„Sign-off“-Process for vehicle use at body manufacturer or use of aggregates at external supplier
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Main role content of Design (ED) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Principal feasibility Specification
Concept selection (DtT)
2. P
External
implem. specs for ext. development
Component req. specs
Confirmation req. specs in house develop. (implem. specs.)
Series supplier w/ development content *) Finalization design 18 15 12 9 6
C=series tools („P“) Design
2)
*) Cooperation with series suppliers with own development by paying development costs (collaboration until ‘P’-release). Development scope is specified and documented in component/procurement schedule, before QG8 (if necessary: special processes can be added)
2)
Finalization development
Specific. „V“
Change management Components
Analyze testing results
Components
Entire product
A-sample
B-sample
Release „_“
Configuration codes
Components
Entire product
C-sample
Entire product
D-sample
Interfaces (cooperation) Comp./procurement schedule1)
Develop. suppl. (for req. specs) + basic list all components/ parts
Series supplier with C=series tools
C=series supplier with prototype tools
Preparation series suppliers
1) Component/ procurement schedule are specified by project lead in cooperation with purchasing and development department. If necessary, additional departments (e.g. suppliers management) are involved. 2) Simulation (Role EC) + review manufacturability (role MP)
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0
Main role content of Documentation (EV) S
10
Concept selection
A-sample Build up BoM
Build up frame for BoM
9
8
7a
7
6
C-sample
B-sample
4
2
1
„V“
5)
3)
1)
‚V‘
7) 4)
Awarding series supplier and series tools ‚P‘
C=series tools Initial stage Product configuration
15 12 9 (‚P‘)
6 6)
Documentation Configuration codes
„_“
6
‚E‘ 2)
b (‚_‘)
a
‚_‘-Release „w/o restrictions“
c b
c
a Parts without required tests:
‚_‘ release after final clarification with suppliers
For MB-vehicles 1) ZS-B 2) Z1-Z5 for B-sample 3) ZS-C 4) Z1-Z5 for C-sample 5) ZS-D 6) F2-F5 for special cases 7) F1-F5 regular
0
BoM for pre-tryout
18 15 12 9
Document. for procurement
3
D-sample
Reference BoM
Document. for simulation
5
b
Parts with required tests: ‚_‘ release after short test of part from series production tool
c Then finalization of ISIR until Gate 3 BoM = Bill of material
(done by suppliers mgmt (role SQ) Next: Release for production
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2. P
Main topics
Main role content of Testing (EP) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Assessment innovations and concept
General
Def. Requirements from testing concept selection (DtT)
2. P
Proj. req. specs
Ensuring/ evaluation req. specs. Comp. req. specs. Req. for prototype tests Ensuring test rigs
Test plan
General test plan (DVP&R)
For B-sample
For C-sample
For D-sample
from prototype tools
Comp. tests
Optional for „-“ release
C=series tools Install measuring technology Tests entire product
Acc. testing. (Optional)
A-sample
B-sample
Acc. testing.
C-sample
Certification Customer driving tests
D-sample Daimler Trucks | 62
0
Main role content of Calculation (EC) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Principal feasibility
General simulation
Concept selection (DtT)
Components
2. P
Req. specs
Entire product Implem. specs
Simulation Components
18 15 12
9
6
Verification attending to comp. testing
Simulation
Ensuring Certification
entire product
Attending change mgnt. from D-sample tests Verification attending to entire prod. testing
A-sample
B-sample
C-sample
D-sample Daimler Trucks | 63
Main role content of Electrics/Electronics (EE) Main topics
S
Concept selection
10
9
8
7a
7
6
5
4
3
2
1
Principle feasibility Concept selection Specification
Integration advance development Project req. specs.
Project implem. specs.
Component Req. specs Implem. specs.
2. P
External
Contribution
B-sample
Specific. „V“
C-sample C=series tools („P“) *
*
Simulation
Hardware
D-sample Finalization design 18 15 12 9 6
Simulation
Release „_“
Configuration codes
Finalization development
Package space validation Testing Homologation samples Production tests SOP
Integration diagnostic concept Requirement specification Comm.matrix. Overlapping synchronization
SWIntegration
Software is ready for…
4
SWcomp.
2
Concept
1
Final Release Test
3
1
Specification 2
Specification
Implementation 3 Integration 4 Application/Test
Last bug fixing Test for final release
incl. summer/winter test
*
Simulation is carried out in role EC
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0
Main role content of Styling (ES) S
Main topics
Concept selection
10
9
8
7a
7
6
Market trends Concepts
Pre-selection
Color
5
4
3
2
1
0
Decision
Sketches 1:1 Prop. 1:4 CM1) Selection CM1) Styling Exterior
Models StylingFreeze2)
Styling freeze Management release
2. P
Styling decision
B-sample
Data contr. model „Class-A Data“
for C=Series tools C-sample
DCM2 DCM1 DCM final Series
Market trends Sketches
1:1 Prop. Selection CM1)
Styling Interior
Models Concepts
1)
CM: Consolidated model
2)
Pre-Selection
Color
Only in case of C=Series tools, which have influence on Styling
Decision
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Main role content of Thermodynamics (ET) Main topics
Req. and impl. specs.
2. P
Design components
S
Concept selection
10
9
8
7a
7
6
5
4
3
2
1
Contrib. Proj. requirement specs Components Req. specs. Implem. specs.
A
B
C
Finalization release
Principle feasibility Concept
Concept selection
Detailed concept for vehicle specific variants
Detailing
Data performance maps
Data set
Def. u. decision of requirements for tests and test rigs Application Test
at 1-cylinder
Detailed optimization engine – vehicle. on rig test (B50) Engine/aggr.carrier (C20 - C50)
Sys.integration
A-sample
in aggr.carrier (B100)
B-sample
Data for flashing on line
Validation in certification run
in target vehicle (C100)
C-sample
D-sample Daimler Trucks | 66
0
Main role content of Purchasing Equipment (PE) Main topics
Specification
S
10
Concept selection
9
8
Forecast for proj. seq. specs.
7a
7
6
5
4
3
2
1
0
Confirmation for proj. implem. specs.
Budget planning
External development partners
Building contractors
Logistics service providers
2. P
Further awardings
„P“-releases from development
18 15 12 Suppliers for manufac. Equipment
9 6
RfQ for manufacturing equipment suppliers 18 15 12
Assessment quotes / awarding
Series tools. C=series tools
9 6
Regular awarding
Interfaces (cooperation)
Comp./ procurem. schedules
Planning C=series tools In house parts
Preparation RfQ for manufacturing equipment
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Main role content of Purchasing parts (PP) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Procurement strategies on supplier base Strategy
Assessment of market environment (DtT) Contribution for Req. specs Concept competitions
Develop. suppliers Specification
*) Cooperation with series suppliers with own development by paying development costs (collaboration until ‘P’-release). Development scope is specified and documented in component/procurement schedule, before QG8 (if necessary: special processes can be added) see role ED
Series supplier with development content *)
Development contracts
2. PEP
„P“-releases from development here „E“-release
18 15 12
9 6
RfQs with drawings Series suppliers2)
18 15 12
Assessment of offers and series assignments If necessary further negotiations Series tools Prototype tools Process for C=series suppliers
9 6
Series purchasing contracts Purchasing contracts for after sales
Regular series awarding
Interfaces (cooperation) Comp./ procurem. schedules 1)
Develop. suppl. (for req. specs) + basic list all components/ parts
Series supplier with C=series tools
C=series supplier with prototype tools
Preparation series suppliers
1)
Component/ procurement schedule are specified by project lead in cooperation with purchasing and development department. If necessary, additional departments (e.g. suppliers management) are involved.
2)
Series assignments (LON) LATER tooling process is started. Further negotiations will be set up together with cost planning (role )
Daimler Trucks | 68
0
1.
Time critical path
70
2.
Integration and innovation
71
3.
Specification process
72
4.
Sample logic
73
5.
Supplier decision and tools for C-Sample
75
6.
Releases along the Samples
76
7.
Maturity level logic
77
8.
Releases: Requirements and consequences
78
9.
Tool process
79
10.
Important milestones of the process chain
80
11.
Phase of production tests
81
12.
Ramp-up methods
82
13.
Synchronization of truck and aggregate with an example
83
2. P
Page
3. Methods
2.4 Main topics and detailing
1. Overview
2. Product creation process (P)
Daimler Trucks | 69
Time critical path in the product creation process Project scope Project and Series B-Sample and Concept decision Comp.req. suppl. available, working directions (Proj. req. spec.) specs pre-selected Proj.implem.spec
10
9
8
7a
C-Sample available
7
6
100% Finalization customer ready parts Market launch Product Design start of prod.tests SOP completed reliability
Finalization of LL tool release
5
4
3
2
1
S
Product finding and -definition
Proj. req. Project impl.specs specs Product Production concept Prod. req. Sys.+Comp req. Sys.+comp. implem. specs. specs. specs. Production. Detailing production concept req. specs. Styling contracts decision Dev. suppl. 1:4 Models 1:1 Models Packaging/DMU-verification
Productdevelopment
Concept design A Analysis ASample
Test A-Sample
Finalization Design
DCM-Class-A
V / EB
E / EC
Optimization B C Analysis C-Sample Release C
Design status B Analysis B-Sample Release B
Comp.test
Styling freeze
Component test Assembly
Long lead
Test B Sample
Required confirmation…. Short lead Not necessary needed “_” P/A
Verification CD Verification of certification Release logistics
Series release D
Component test Assembly
Accelerated test
Release Product configuration Test C Sample
Test for product release
Cert. run
Series suppliers with proto. tooling
Test D-Sample
Product release in-house parts
Series suppliers with C ≙ series tooling1)
Tool ordering
Ramp-up/ Series prod.
2. P
Work. dir.
Process capability
Tool making Approval of manufacturing equipment
PT1 PT2 PT3
Series production
V / EB
Time critical path
DCM=Data Control Model PT=Production test
Releases: MB Trucks + Fuso/ DTNA
1) Only selected parts
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0
Integration of Innovations into the product creation process Innovation creation (component)
Idea generation
IQG2
Preliminary study Definition of target product/ segment
Productcreation
Long term time scheduling
Functional Proof
Integration Suitability within target project
•
IQG0
IQG1
Innovation project
•
Future Projects input of Advanced Engineering
Hand-over of mature innovations to product creation process
Confirmed List of Future Projects
10
9
Securing : •
Technical suitability of the component for the target product
•
Component maturity is assured (technically and economically)
•
Consideration of marketing and production requirements of components
•
Compliance with legal aspects
Optimizing: •
Steering of innovation projects
•
Responsibilities of technologies, developed by advanced engineering, are transferred to series development (Product projects)
Concept selection
Synchronization: • At gate “9“ and “concept selection“, the corresponding contributions will be assured by Advanced Engineering and triggered by Product Planning • Target for IQG 0: no later than “concept selection“, if possible to gate “10“. Hand-over points for concept relevant innovations; hand-over for other innovations can be later
Daimler Trucks | 71
2. P
IQG3
Project Maturity
S
Innovation Draft
Objectives of Innovation QG
Specification process 10
9
Level
Project
Sub-chapters
2. P
Entire product
8
7a
7
Requirements Working directions
4)
Systems
Components
Production (exemplary for following sub-projects)
Project req.
Properties of the entire product
Confirmed implem. spec of entire product
Entire product req. specs
Workshops concerning product and production concept (DtTWorkshops)
Production concept
Project implem. spec 2), 3)
spec1),3)
System req. specs
Req. Specs. Production (craft level)
System implem. specs.
Offers (External development) Component req.Design specs (Internal development)
Component implem. specs.
Production concept on work station level
Approval 1) Requirement Specification: Defines “ what“ the product is expected fulfill Requirement specification, order 2) Implementation Specification: Defines „how“ the requirements will be fulfilled Commitment against customer 3) Project req./implem. Specs. : Aggregates, besides the product information, all sub-project contributions 4) Entire product: Equivalent to project scope, i.e. truck, engine, axle, transmission etc. depending
Daimler Trucks | 72
Sample logic: Definition A-/ B-sample B-sample
Manufacturing
•
Made by prototype tools or hand-made (not necessarily made out of target material)
•
Made by prototype tools (not necessarily made out of target materials)
Application
•
Functional and independent component tests without environmental conditions (within the aggregate carrier also possible)
•
Installation tests and functional tests are carried out on the test rig, e.g. within entire aggregate or vehicle.
Objectives
•
Assurance of innovations (conclusion of advanced development)
•
Management of the decision on alternative, competing product concepts
•
Existing requirements regarding functionality and envelope space have to be fulfilled (perspective: Requirement specification). Requirements should also be evaluated with respect to the component (life time / durability capability is not focused)
•
2. P
A-sample
Confirm: Function Forecast: Reliability Function, geometry, surface, connection technique, haptics, mechanical and electric requirements, temperature tests, basic durability etc. have to ensure future characteristics of the series product (suppliers have to show all derivations)
•
Initial cost analysis on parts level is available
•
Initial status of the FMEA is considered.
•
Basis for make or buy decision and the production concept.
Daimler Trucks | 73
Sample logic: Definition C-/ D-sample D-sample
Manufacturing
•
Functionality and product properties are similar to series: Fine-geometry (radiuses, form, grain…) and used materials are very close to series (not necessarily made with series tools) • Principle of manufacturing: Master-forming and shaping are close to series ( not necessarily made with series tools)
• • •
Application
• •
Reliability tests on (overload)-test rig Tests with first target vehicle
•
Objectives
•
Assure installation, functionality, properties, endurance and reliability. Surface quality is close to series. Envelope space requirements and the positioning of points meet assembly requirements. Reach drawing geometry “Series“. Assure a maturity so that production equipment can be ordered. Ensure that tools are manufactured
2. P
C-sample
• • • •
Design with series-production status Produced out of series material with series tools Products to be built within pre-tryout / production tests • D1-sample: first parts from series production tool with series geometry and materials, which were manufactured under close to series conditions • D2-sample: as D1, but produced under full series conditions.
Examination of all factors, relevant to the product.
• •
Suppliers have to complete all quality-relevant tests D1: Last confirmation though development, type testing, pilot series (pre-tryout), Homologation • D2: Proof that part is conform to series documentation (part successfully sampled (ISIR), maturity for production tests/tryouts is obtained.
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Supplier decision and tooling for C-sample Development
In-house Development Scope
Supplier
Prototype Tool
Series tool
Development Supplier
If contracted with LOI or development and supply contract
If necessary 1)
Design Status close to series3)
Series Assignment
Supplier Prototype Supplier
Standard 2)
Series Supplier
If competence of supplier important for C-Sample and know-how has to be transferred to series
Series tool
Final Design Status 3)
If a development supplier cannot deliver prototype parts
If necessary1) Final Design Status 3) Series Assignment
Design Status close to series 3)
2. P
No changes of contract Prototype Supplier
Prototype Tool
One-time Assignment, no Series Assignment (internal determination)
One-time Assignment
1)
Coordinated and defined by Project Lead in the Procurement Schedule at Gate 8 Issues according Safety and Quality Engineering and Quality, Issues according Costs Cost Planning, if necessary Purchasing
2)
Forward Looking necessary on part Level: If supplier change from C- to D-sample doesn‘t jeopardize the SOP. Parts have to be available for certification and sample parts evaluation in the demanded Quality.
3)
For MB-Trucks: close to series corresponds to E-Releases – Final Design Status corresponds to „P“-Release
Daimler Trucks | 75
Releases are granted with the samples 10
9
8
7a
7
6
5
4
2
1
0
100% parts „_“
100% parts „E“
S
100% parts „V“
3
Engineering release of entire product
100% ISIR Concept A
Design
2. P
Analysis
Manufact.bility simulation
Drawing release
Design B-sample components
Analysis A-sample
A-sample IQG 0 Components
Testing Entire product
Optimize BC Analysis B-sample Release B
Comp.test Test A-sample
Analysis C-samples
C-sample
B-sample Series suppliers for C-Sample (only selected parts)
Simulation/ review manufac.bility
Release C
Component test Buildup
D-sample
Confirm CD
„P“
Release D (Finalize design)
Component tests
Test B-samples
Buildup
Accelerated test
Finalize Docs. Confirmation
Test C-samples
Build-up Confirm. Cert.run
Confirmation run D-samples
Delivery D1 Series supplier with prototype tools Series supplier with series tools
Product release in house parts
2)
„R“
Parts to be confirmed 1) Delivery Prod.tests
100% parts „P“ •
• •
1) 2)
Maturity levels for documentation are matched with development phases Progress of components design in the component application structure Maturity level describe the „finalization of design“: A-sample 1), B-sample (‚V‘), C-sample (‚E‘), D-sample (‚P‘), finalization of development ‚_‘ The final release of development, is done as „Engineering release of entire product“ by the responsible person for development before start of production tests (QG3)
• • • •
Supplier management activities start simultaneously with the development processes Planning of product release starts with „P“ and awarded series supplier Finalization of initial inspection report requires ‘_’ All in house and purchased parts have to be assessed „green“ before SOP (ISIR).
For A-Sample documentation in EDS is not obligatory Preliminary release is done with risks in case tool lead timing exceeds end of C-sample accelerated tests and is released by project leader
Daimler Trucks | 76
Component related releases (maturity level logic) For MB: compare to process instruction V019E042
1)
X
Content
2)
(no EDS doc.) Finalization Design „A-sample“
V
E 2)
•
Integration of innovation/technologies into series development (entire product). • Alternatively, competing concepts are assessed regarding their series development feasibility
•
Functional validation of determined technical concept from the innovation phase • Fulfillment of requirements concerning functionality of components/ software and the required package space are being targeted
•
Procurement parts/ EE-content as a prototype to ensure innovations and concept investigations (Bsample)
•
Procurement parts / EE-content as prototype to ensure the reliability and durability (C-sample). Manufacturing process/ material as close to series as possible (prototype-tools)
•
Finalization Design „B-sample“
E
Consequences
E 2)
•
Testing components/ system/ EE-content of entire product with respect to reliability and durability.
Procurement of parts/ EE-content as a prototype part to ensure innovations and concept investigations (A-sample) • Realization of concept decision
Finalization Design „C-sample“ A 2)
Finalization Design „D-sample“ („C=Series“)
„_“
2)
Finalization of development and documentation
1)
Change Management
P
•
In principle finalization of design activities Start of change management only in case of occurring damages during testing or manufacturability problems in the production process. • Finalization : Drawings, part numbers, variants, bill of material incl. product properties, components coded in bill of material (SAA), review of manufacturability, materials and process parameter. • Specification if parts have to be confirmed out of series prod. tools. • Finalization up to gate 4 (or gate 6 for C=Series tools)
•
•
Finalization of development Close to gate 3 with sufficient timing to finalize product release • Proven reliability (statistical securing of released design status) • In case of necessity short term confirmation of part from series prod. Tool is possible • For purchased parts series supplier is awarded
•
•
•
For A-sample documentation in EDS is not obligatory
2)
MBTrucks/MFTBC global
DTNA
RfQ, selection & contractual commitment of series supplier. • Awarding of series tools or series manufacturing equipment • Procurement parts from series prod. tools. (D-sample parts for component validation, pretryout, homologation, if necessary C=Series tools) • Finalization of configuration codes („V“) Finalization of product release activities Procurement for production tests • Parts/EE-content can be procured for the defined application incl. spare parts • Release of configuration codes („_“)
Daimler Trucks | 77
2. P
Maturity Lev.
Requirements for releases and consequences of delays Release Consequences of missing /delayed releases • 1)
X
2)
• • • •
2. P
•
V
E 2)
• • •
E P
E 2)
A 2)
• • • •
„_“
2)
• • • • •
Connection of ISIR and ‚_‘- release
No results from A-sample testing Restricted evaluation of requirements regarding space, function, model variants, target weight ... Missing input for concept selection Req. specs./implem. specs. phase (request develop. suppl.) delayed Delayed start of in house development Cost planning delayed
•
No procurement of prototype parts Assembly/Testing of prototypes not possible Delayed prototype tests (shortened test period, statements deduced from test results with lower quality, …)
•
Its not possible to assign a) Series suppliers incl. tools b) manufacturing equipment Punctual installation of manufacturing equipment is at risk Increased risk regarding time, budget and resources Parts evaluation not completed Delay of production tests/ tryouts Product liability risks Spare parts can not be ordered Delay of sales process/ launch Assembly test has to be done manually
1) For A-Sample documentation in EDS is not obligatory 2) MBTrucks/MFTBC global DTNA
•
•
•
Only parts with drawing release ‚_‘ and product 3) release (ISIR ) can be assembled into customer vehicles. Product release process starts before „during“ or after ‚_‘ –release Important: In case the product release process is started before ‚_‘ –release, its important to assure the equality of 3) released and PPAPed ZGS (drawing version). If the initial samples are requested based on ‚P‘, then ZGS of ‚P‘ and ‚_‘ have to be identical. Otherwise a change management process is necessary. Product release should not be finalized before ‚_‘ for the following reasons: • Customer readiness would be confirmed, despite an insufficient maturity level. • In case of any ZGS changes up to ‚_‘ the product release becomes invalid. • After product release, parts can automatically be ordered by machine, in this case ‚_‘-release shouldn’t be missing
3) ISIR: initial sample inspection report, ZGS: Zeichnungsgeometriestand
Daimler Trucks | 78
Rule of thumb for tool process ( see: purchased parts, in house parts are identical) 4
Finalization development
Further securing until finalization of design
C-Sample testing
no
P A Finalization design
–
Release Develop. docum.
Development
Purchasing (purchasing of parts)
Suppl. Mgmt. (SQ)
Does the part has to be confirmed out of series prod. tools?
Docum. for series order placement and tool manufacturing
Certification run
TBT-D1
Date of delivery
Optional confirmation run D1-Components 2)
Finalization purchasing 2)
ISIR Start
PPR: Product rel. 4)
Production
3)
D1-Sample
Finalization Dispo. Production
tests
D2-Sample = Initial sample
Tool process Supplier
–
Assembly of entire product for certification
Hand-over of finalized drawings to procurement incl. unit numbers (from SM) Request for Quote Series suppl.
yes
2. P
Adequate securing (reliability 1)
3
Design
Optimization Assembly product /process Testing series tools Initial part (not customer ready)
1)
Corresponds to at least accelerated tests for vehicles or overcharging test rig for aggregates D1-sample parts for confirmation are prototypes, have to be purchased at prototype prices (not series purchasing contract) 3) Date has to be determined for each part – can be before or after ‘_’. ZGS has to be identical. 4) PPR: production process and product release. Initial sample test report is written „ISIR“ (Product „green“, process min. „yellow“) 2)
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Link between release of parts, codes and sales C-Sample available
Finalization of LLtool release
6
5
100% customer ready parts, start of prod. tests
Finalization Design
4
1
Finalize accelerated tests or overcharging test rig
Provision D1-Sample parts
SOP
3
Finalization development
2
C-sample testing Finalization development
Finalization design
2. P
Normally releases are staggered depending on tool manufacturing time (months + time to request calculated up to D2-part) Milestone labeling: MB Vehicle F1(18) F2(15) Fx(13) F3(12) F4(9) F5(6) Aggregate: long/medium/short
1
2
Drawing „P“ documented
4
Finalization product release
Request Series request Manufacturing series tools
Optimize tools
Max. tool time
Assembly1) Confirm. D1 entire product and certification
Sales documentation Test vehicle configuration for production tests Includes preparation and implementation of pre-tryouts
D2-part
3 Confirm. D1-components
Configuration codes release „V“
1)
6
„_“ documented
5
5
Confirm. „_“ Finalization 1
2
Pre-run supplier Preparation location
Definition:
3 7 71
2 3 Production tests
1 All confirmation relevant parts, according to their tool lead time, have to be released until 1 (_Fx for MB Trucks), so that they are available as D1-part for 3
(especially aggregate projects: if 100% parts are relevant for confirmation this is Gate 4 Finalization Design (100% parts ‚P‘) Careful: if 100% parts are relevant for confirmation, 2 is at 1 Date of delivery D1-sample components Finalization of first ‘_’ releases (parts not relevant for confirmation) With „Final. Design („P“-parts) configuration codes, and all their interactions, are released („V Code“) and with „Final. development“ (as „_“-parts) final confirmation occurs with „_“. 6 Final. development (100% parts ‚_‘), corresponding to date of delivery of D2-sample: Start finalization product release 7 Start production tests 2 3 4 5
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Phase of production tests1) 2 Production test 1 MM Production test 2 MM Production test 3
MM
Test Analysis/Optimization
Prod. Test 1: Line complete
Prod. Test 2: Quality
Prod. Test 3: Cycle time
•
station sequences/ stations in automatic mode. • Reconcile manufacturing equipment and product
•
Ensure surface and dimensional requirements • Ensure bonding techniques: welding and riveting
•
Validate work instructions • Staffing complete and start employee training
•
Fulfill pre-delivery inspection • Product- and process release of entire product
•
•
Ensure process flow
Ensure product quality
1) DTNA: Pre-Series, productions stages are considered before final assembly
Ensure process short term process capability of entire product • Ensure and optimize production peek (number of units) Ensure availability of parts and components • Validate logistics • Employees trained within production tact
Ensure process cycle time
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2. P
3
Four defined ramp-up methods linked to projects according to their degree of complexity 10
9
8
Special Milestones MB-Truck
KB
Z1
Z5
For B-sample
Category 1
Ex
(Product project)
6
7
7a
Definition vehicle
A
Z1
Z5
Definition vehicle.
2. P
Category 2a
Ex
Prototype
Sample vehicle
Sample vehicle Pre-series vehicle (FX)
MP
Opt.: Definition veh. Definition vehicle
PT1
PT2
Pre-series vehicles (FE)
Category 2b (Difficult Start of production)
Ramp Up
Ramp down
Ramp down
Series (FE) Optional: Sample vehicle
MP
Pre-series vehicles (FE)
Category 3
Ramp Up
Ramp down
Series (FE)
(Easy Start of production) Opt: Pre-series vehicles (FE)
Ordered by internal customers of Daimler Trucks Note: Categories are explained for vehicles, but they can also be applied for aggregates!
Ramp Up
Sample vehicle Opt: Pre-series vehicle (FX)
Daimler Trucks internal*
Series (FE)
Series (FE)
Opt.: Pre-testing veh. Opt.: Prototype Sample vehicle
0
PA
PT3 MP
1
For D-sample
Daimler Trucks internal*
(Complex Start of production)
2
3
(FA) F1 F2 FX F3 F4 F5 (FE)
For C-sample
Pre-testing vehicle
4
5
* e.g. Show Trucks, Engineering Tryout, Customer Demonstration Unit, …
Ramp Up
Ramp down
Ordered by external customers
Pre-series vehicle (FE) = parts are 100% customer ready external customers Pre-series vehicle (FX) = parts are not100 % customer ready only for internal customers PT1, PT2, PT3 = Production tests D-Sample = Depending on quality possibly also for external customers (release required)
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Truck and aggregate projects are linked through important processes and defined synchronization points. 10
9
8
7a
7
Vehicle req. specs
6
5
4
3
2
Vehicle implem. specs Comp. req. specs
Comp. implem. specs.
Assembly B-sample Test (Functions)
Assembly
Certific. run
PT1
PT2
PT3
Ass- C-sample Test embly Function + Reliability
Sys.-LH
Workshops
Contents of Synchronization 10
Aggregate
Aggr. implem. specs.
Design B
LL-tool release
req. spec
9
8
impl. spec
7a
Depending on the project scope in a vehicle or target vehicle
7
Aggr. req. specs. Comp Com. implem. req. specs spec
6
B-sample test
Series tooling, but not necessarily: •Series machines •Series location •Series process/ tact
Into a target vehicle
5
C-sample test Components available for target vehicle testing
4
Aggregates certified after PT2 •Series tooling •Series machines/ location •Series process •Series quality •not yet series tact
3
2
D-pretryout Cert. run
Only applicable for: a) Modification of aggregate in new truck (aggregate with minimum maturity level D) b) New aggregate in modified truck (truck with minimum maturity level D) c) New/new combinations require modification (see following page)
PT1 PT2 PT3
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2. P
Truck
Example: Synchronization „New/New“ over various aggregates 10
9
7a
8
7
Concept
Vehicle
Vehicle spec. book Sammel-AEF
100% V ATS spec. book
100% E
100% P
1
IF K1-5 Vehicle Simulation
6
PA Brackets
IF K1-5 Vehicle Simulation
3
Assembly B
2. P
After treatment of exhaust gases Engine
7a
8
A
Concept
100% „_“
V
IF
E
IF
Assembly
3
P
“_“ Complete System
Drawing PA
DVerification
Testing C-Sample
Drawing PA
Complete System Validation 2000h
Testing B-Sample
Tooling Timeline
Prototype C
IF – Interface Freeze LS – Load Spectrum Mat. – Maturity ATS – Aftertreatment System PA – Parts Availability TO - Tryout
ATS B50 Engine B0
2
Simulation D
Drawing
Prototype B
TO1 TO2 TO3
4
Calculation B Drawing ATS-Housing
Homologation
Design D
Design C
Design B
PA Brackets
C-Sample Test (Function)
5
Simulation C Build-Up A-Sample
6
1
K1-5
Corrosion C-Sample Test (Reliability) Vehicle Rough Road Mat. C
6
System Final spec. book Component Supplier spec. book Concept eval.
System spec. book Component spec. book concept competition
10
2
LS Mat. C
Assembly C
B-Sample Test (Function)
7 IF
IF
Pre- 4 LS Mat. C
LS MB
Pre LS Mat. B
2
6
1
PA Brackets
2
9
3
4
Vehicle final spec. book
Vehicle Components Specification Book • Packaging • Interface • Bracket Concept • In- and Outlet Variants • Input forces/ Acceleration based on predecessor vehicle
10
5
6
ATS C100
ATS B100 Comp. Sys. B100 Engine C0 (Engine + ATS)
Engine C50
Product Release PPF Components Complete System
2
5
Comp. Sys. C100 (Engine + ATS)
Cert. run
1
Agreement for synchronization of K-Dates (K1, 2, 3, 4 or 5) between vehicle and ATS after concept competition.
2
In case of a new ATS design and new vehicle project, enough time needs to be considered between vehicle testing and correlating design freezes.
3
Load spectrum based on A-Sample vehicle and B-Sample ATS
4
Load spectrum derived from B-Sample vehicle and C-Sample ATS
5
Data transfer between engine thermodynamics and ATS
6
Agreement between Vehicle and ATS regarding relevant components as well as release planning to ensure ATS pre-testing
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3.Methods 1.
Page Goals and principles of CVDS 3.0
1. Overview
1. Overview
6
2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/ 32 roles
9
2.2.
Quality Gates for truck- und aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks during project time
39
2.4.
Main topics and details
72
Planning Assessment Reporting Steering
87 90 95 97
2. P
2. Product creation process (P)
3.1 3.2 3.3 3.4 s
3. Methods
3. Methods
99
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CVDS methods
Planning What do we have to work on? When should this be done?
Assessment s
1
2
3
What's the status of my processes? Am I able to solve my problems?
4
PM-Software
3. Methods
Steering Solving problems with decisions
Reporting Visualization of status, problems and other open issues.
Execution of integrated product steering
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CVDS method planning: Planning Implementation steps Implementation CVDS 9
A. Creation Framework Schedule
8
B. Extension Master Plan
0
C. Optional detail planning
Project leader A-Level Sub-project leader B-Level
• The critical path and Quality Gates will be developed in collaboration with the product planning / project lead. • Critical path means to identify the activities which drive the duration of the respective process modules. • The position of the Quality Gates is to be derived out of the critical path.
• As soon as the project team has been named, • planning will be detailed for every functional department respective role (based on the Framework Schedule) I.e. through discussions of the CVDS content with the project team, the project specific Master Plan is to be created.
Concluding more detailed schedules can be created in RPlan in reference to the overall logic of the critical path and Master Plan.
• The result will be transferred into RPlan.
*) RPlan is the standard-IT-tool for planning, steering and reporting within CVDS
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3. Methods
Leader of working packages C-Level
CVDS method planning: Roles and responsibilities within the P Project leader •
Agrees the strategy, objectives and goals for the project with PEC.
•
Plans project in of time, cost, quality, targets and resources together with Project Core Team. Performs the overall, cross-functional operative management of the project to ensure that project objectives are achieved. Specifically manages and tracks timing, budget, variable cost, implementation of project scope against targets. Responsible for ensuring that requirements and Quality Gate criteria are successfully met. Reports project progress to PEC to ensure the project’s overall direction and integrity. Performs management of the risks of the project, including the development of contingency plans. Manages stakeholder expectations and removes roadblocks. Directs and motivates the project team.
•
•
3. Methods
• •
• •
Sub-project leader •
•
• •
•
• •
Prepares plans and resource requirements for the team’s work and agrees it with the subprojects and project manager. Serves as coordinator, providing task and technical leadership, and facilitates the execution of his portion of the project plan Implements gate-criteria in the respective functional area. Reports to and advises the project manager of success or deviation from plan. Identifies and advises the project manager of any roadblocks and risks associated with a work package. Initiates corrective action where necessary. Communicates with management in the functional area. Motivates the team and monitors work to ensure quality control.
Leader of working packages •
• •
• •
Provides the required expertise or specialist knowledge to the project, in of fulfillment of targets. Carries out agreed activities at the assigned times. Assesses and communicates process progress (expected targets) regarding execution, issues and risks to core team leader or project manager. Resolves technical problems related to his or her functional area. Introduce new processes, where necessary, and develop a high level implementation plan and design measures and systems to ensure that the new processes work effectively
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CVDS method planning: Role and milestone abbreviations Role abbreviation
7a
7
QE
060
Process start Process end
Example Role-ID
7a
Process-ID
7QE060b
7a
QE
All risks
060
a 7a_7QE060
FMEA initial position (components)
Quality Gate Role-ID Process-ID Milestone-ID
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3. Methods
7aQE060a
Milestone abbreviation
Advice to test planning 7QE060c List of measures
CVDS method assessment: Connection of project planning and assessment Project planning
Project assessment
Project leader A-Level
3. Methods
Sub-project Leader B-Level
Assessment in RPlan
Process1)
2)
target)
Process1)
2)
target)
Process1)
2)
target3)
•
The Master Plan consists of various roles:
•
Roles s are described within the process
•
Each process (1) has a target (3), which has to be reached. If necessary processes are subdivided by milestones. Additionally each process is described with a detailed information(2).
• • • •
•
Traffic light status Status Measures Degree of fulfillment
The assessment of a target includes traffic light status, explanation of this status, measures and the degree of fulfillment
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CVDS method assessment: Future-oriented assessment of processes in RPlan Gate n+1
• • • •
forward-oriented -1 months
ca. + 6 months
The implementation of all activities, out of project master plan, are continuously assessed with traffic lights. Regular assessments with project serve for status assessment and to derive counter measures. Assessment is carried out for all processes within the timeframe between last month and the following 6 months. Explanations and measures for traffic light status are added. Progress documentation can be added to RPLan as linked documents.
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3. Methods
backwardoriented
•
Gate n-1
Role 3 Role 4
Gate n
Role 1 Role 2
Assessment
CVDS method assessment: Visualize the target fulfillment of a process using future-oriented assessment 3) Assessment process
Traffic light definition Color
No
Measures defined
3. Methods
No
Target met/ Achievement secure?
1) See Checklist on following page 2) Target always refers to Time, Quality, Costs 3) Corresponds to CVDS monthly reports in RPLAN
HELP NEEDED • The status of the specified content does not fulfill the defined targets2) • There is no secured and confirmed action plan that enables the fulfillment of the following customer process targets
Measures secure?1)
Yes
Process
Description
Yes
PROBLEMS – BUT WE HAVE A GOOD PLAN • The status of the specified content does not fulfill the defined targets2) • There is a secured and confirmed action plan that enables the fulfillment of the following customer process targets without implication on the project
EVERYTHING OK • The status of the specified content does fulfill the defined targets2) • The defined prerequisites for the following customer process are fulfilled
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CVDS method assessment: Securing of measures is verified by the following checklist Checklist
Yes
No
Effect
Were the measures approved by the process customer?
Measure is secured
Are all resources, necessary for the measures’ execution, available?
Is it possible to implement the measures during the agreed upon timeframe? (Max. until next QG) Do Project targets remain unchanged (time, quality, costs)?
yes All questions answered with „Yes“
no Measure is not secured
Is it possible to make up for delays und can the overall project schedule remain unaffected?
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3. Methods
Do we have clear evidence of the measures problem solving capability?
CVDS method assessment: Project-status 1): Compare planned and real status Example
Procedure
• •
Assessment date
A target curve is defined A target area/tolerance range is defined for the target curve.
Planned progress
Progress
Green: Status according to plan Yellow: Minor deviation – still acceptable means: in yellow area Red: Significant deviation - unacceptable means: in red area
100%
Real progress 3. Methods
•
Start
End
Process step
1) Corresponds to assessment of MLMR
• • •
For each process target status and tolerance area have to be considered individually. For each assessment date real status is recorded The real status assessment determines the traffic light In case of a „yellow“ or „red“ assessment, measures need to be defined, to get back on planned track
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CVDS method reporting: Monthly reports Hierarchical assessment and standard reports
Project overall
Sub-project
Pre-requisites and procedure QG-Reporting Committee
•
The logic of assessment is bottom-up (hierarchical) oriented
CVDS based Standardreport
•
For this, a standard report with following contents is available:
Connected Projects
•
Overall project status report: Traffic light for entire project and its connected projects
•
Project leader report: Traffic light of entire project and sub-projects
•
Monthly report: All project activities within reporting frame -1/+6 months
•
RR-report (only in QG-report) : Report of reporting relevant criteria per QG
Working packages
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3. Methods
Bottom-up Reporting Process
CVDS method reporting: Reporting for the QG report Logistics (TL)
Last QG
Assessment of previous QGs
2
Overall assessment of each sub-project. Reflect quality and costs (=RPLAN reporting and assessment)
3. Methods
1
3
Subjective, future oriented assessment of following QG
Current Status
1
2
3
Gate n+1
Role(s) Logistics
Next QG
Gate n
Gate n-1
See guidelines „PEC-Reporting“
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CVDS method steering: Decision based on reported red status example What is steering
Reporting committee
Reaction to failed plan fulfillment No Yes
No
Subproject leader
Schedule adaption or additional processes to ensure achievement of targets. All this is worked out, planned and controlled in close cooperation with the customer1)
Can we define a measure?
Yes
Team
Changed assessment „Yellow“
→ What are my consequences from assessment? → Make decisions: - Who does what? - How should it be done? → Which measures are implemented?
Assessment „Red“ Changed assessment „Yellow“
1) Project customer, PEC/TEC, OU, decision committee
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3. Methods
Project leader
Can we define a measure?
CVDS method steering: In case of a red light we have 3 options Quality Gate Decision
Options for QG-Decision Measure realization
B
A• Approval B• Approval with conditions/measures C• No approval • After risk assessment, C1
renewed calculation and approval n+1
n
A
n-1
by the PEC C1.1: Adapted target C1.2: Adapted target
3. Methods
and measures C1.1 C1.2 C1.3 1)
C C1 assessment C3
1)
Re-assessment for next Gate • Resubmission until uncompleted or missing C2
Risk
C2
C1.3: No target adaption1)
(Target categories: Costs, Time, Content)
Reference to (ordinarily) volatile, external, not sustainable influences
content is included or solved • Project cancelation/ restructuring C3
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In case you have any questions feel free to :
Name
Region
Role
Yamazaki, Shinichiro
Japan
CVDS-Representative, TA/LCG
Kitagaki, Masashi
Japan
CVDS-Representative, TA/LCG
Graetz, Anton
DDC
CVDS-Representative, TG/ECN
Johnston, Jason
DTNA
CVDS-Representative, TN/OQ
Cusin, Fernando
Brazil
CVDS-Representative, TE/BO
Rai, Amit
DICV
CVDS-Representative, T/ICM
Engineering vehicles and aggregates
Seidel, Karl-Alexander
TP/EVA
Helbig, Angelina
TP/EVL
Gross, Matthias
TP/QMP
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Daimler AG Stuttgart, www.daimler.com www.daimler.mobi
For internal purposes only
/Impressum OMCD Global Process & Project Management Office Daimler Trucks Kevin Bangston Phone +49 (711) 17 39099 [email protected] Stuttgart, November 2011 Kevin Bangston
Dr. Jens Krüger Joachim Mewis Elke Piepenbring Martin Schneider
Phone +49 (160) 8670418 Phone +49 (151) 58613259 Phone +49 (151) 58612597 Phone +49 (160) 8630780
Publisher: Daimler AG Editor: Dr. Jens Krüger, Torsten Awolin Edition 1 (12/2011): 2.000 Ex.
[email protected]
Operational Management Counsel Department (OMCD) Mercedes-Benz Untertürkheim Plant Daimler AG 001 – E202 70546 Stuttgart/ https://sp.app.corpintra.net/sites/00019/CVDSSTandards/ Pages/Startpage_CVDSWiki.aspx
For internal purposes only. All rights reserved. Copying of content, even if only in excerpts, requires a written permission.
Daimler Trucks | 2
Manual Commercial Vehicle Development System 3.0 OMCD – Truck Operating System.
CVDS 3.0 Worldwide – Goals – Content - Benefits Goals – Content • • • • • •
Benefits
Provide methods for integrated planning, steering and • Processes have been optimized: reporting of product projects Early phases (Frontloading), Specification process, release-logic, series and Increase transparency within truck and aggregate projects development suppliers. Worldwide standardization of the product creation • Planning, reporting and steering is integrated into an all process. embracing project management. Continuous improvement of the product creation process by product project application and role specialists. of cooperation and teamwork between and within the projects Develop and guarantee a homogenous understanding on international level.
CVDS 3.0 is the fundamental approach on how we set-up, control and deliver all product projects in Daimler Trucks. From each project lead and project team I expect a selfcommitment to align to this standard. Project specific deviances are to be shown by risk management, in order to treat them with awareness and responsibility.
Stuttgart, November 2011 Andreas Renschler
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Content of the CVDS 3.0 manual 1.
Page Goals and principles of CVDS 3.0
1. Overview
1. Overview
6
2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/ 32 roles
9
2.2.
Quality Gates for truck- und aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks over time
36
2.4.
Main topics and details
69
Planning Assessment Reporting Steering
87 90 95 97
2. P
2. Product creation process (P)
3.1 3.2 3.3 3.4 s
3. Methods
3. Methods
99
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CVDS Product Creation Process • What must be done?
Methods of the Daimler Trucks PM Office • How must it be done?
Lean Project Management Integration of 12 PM modules into the CVDS Framework
• 9 Lean Principles
• When does it have to be done? • Lean Processes (Frontloading etc.)
• Methods
• Quality Gates / Milestones
• Standards
• Process Modules and Steps
• Templates and Guidelines
• Knowledge Database
• Reporting
Leadership Marketing
Objectives
• Best Practices Change Mgnt.
S
10
9 Dt T 1
2
8
7a
7
6
5
4
3
2
1
0
3
Organization
Planning Definition Initialization
„
Steering
1. Overview
Process-oriented integration of PM-methods
Maturity 22
11
33
Organization
Targets 55
66
Time Planning
Project Structure
Risk Management
Resources 10 10
Comm.
88
77
99
Risk Mgnt
44
Costs
Structure
Communication
11 11
Costs
Scheduling Resources
Change / Configuration
Maturity Management
Project Marketing
12 12
Leadership
Successful Project Management
Process based PM in CVDS 3.0
Daimler Trucks | 6
Start – Kick-off
10
9
8
7a
7
6
Requirement/Implementation specification process 1)
5
4
3
2
End of market launch
Product reliability
1
0
Harmonized release logic Tooling process
Frontloading
Integrated
100 % customer Conclusion of Start of ready parts/ development Production Start work (SOP) production tests
Sign off process (on/ off highway)
Synchronization of various projects (e.g. After treatment system to vehicle and to engine) Revised description of target and details for all roles in development
Methods in Project Management
CVDS 3.0
Updated
Start
S 1)
Updated
Project scope and working directions
10
Updated
Project req. spec
9
Updated
Updated
Develop. Component suppliers req. specs pre-selected
8
Standard Requirement Specification = STARS-Project
7a
B-Sample available, Project implem. spec
7
Updated
C-Sample available
6
Updated
Finalization of LL-tool Finalization Design release
5
4
100% customer ready parts, start of prod. tests
3
SOP
2
Market launch Product completed reliability
1
0
Daimler Trucks | 7
1. Overview
Series Principle Concept development Availability BTool Outline feasibility/ feasibility/ feasibility/ Sample/ Availability Crelease Specification Framework Functional Development 100 % final Sample for LL specification specification suppliers are specifications determined
S
CVDS 2.0
Changes in the process model lead to the adoption of new QG definitions in CVDS 3.0
2.Product Creation Process (P)
2. P
1. Overview
1. Overview 1.
6
2. Product creation process (P) 2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/32 roles
9
2.2.
Quality Gates for truck and aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks over time
36
2.4.
Main topics and details
69
Planning, assessment, reporting, steering
87
3. Methods 3.1 – 3.4
3. Methods
Goals and principles of CVDS 3.0
s
99
Daimler Trucks | 8
1. Overview
2.Product Creation Process (P)
10
Module 1: Concept
12
Module 2: Specification
13
Module 3: A–Sample
14
Module 4: B–Sample
15
Module 5: C–Sample
16
Module 6: D–Sample
17
Module 7: Series suppliers for C-Sample
18
Module 8: Series suppliers
19
Module 9: Production planning
20
Module 10: Production Ramp-Up
21
3. Methods
Frame Schedule and standard project organization
2. P
2.1. Product Creation Process (P): Frame Schedule and its modules
Daimler Trucks | 9
Overview about P for truck and aggregate projects Project scope and Start working directions
S
10
Project req. spec Concept selection
QFD
Component req. specs
9
8
Develop. suppliers Project implem. spec pre-selected B-samples available
7a
7
Finalization of LL-tools release
6
100% parts „V“
Working directions
C-sample available
5
Finalization design
100% customer ready parts
SOP
4
3
2
Release of comp. with required confirmation
100% parts „E“
Finalization development
Market lauch Product compl. reliability
1
0
100% parts „_“
100% parts „P“
Market req. Techn. ideas
Preselection
Strategy for develop. depth and general make-or-buy
Prepare and define product- and production concepts
1. Concept
Plant location decision
Product req.spec
2. P
Release of comp. without required confirmation
Make or buy decision
Engineering Release of entire product
Product impl.spec
Component impl. Spec Sys + Component (inhouse+ext. development req. specs Develop. contracts Concept competitions Production Production. Production concept req. specs impl.specs Project Project req. specs impl.specs
2.Specification
Concept A
Design
Analysis Simulation Analysis Manufacturability A-sample Drawing release
Design B-sample components
Components Test Entire product
IQG 0
Component Test Test A-sample
5. C-samples
„V“ Release B
„E“
Build-up
Confirm final design status „P“
Release C
Release D (Finalize design)
Finalization “_“ development work Analyze results of D1 comp. testing
Component test
Test B-samples
Build-up Accelerated test
Test C-sample entire product
Selected P-releases
7. Series suppliers for C-samples (only selected parts)
„P“ Assign series supplier with series tools „E“
100% product release (ISIR)
6. D-samples
Confirm CD
Analysis C-samples
Component test
4. B-samples
Delivery date of first parts from series production tool (D1)
Only vehicles
Optimize BC
Analysis B-samples
3. A-samples
Styling Freeze
Data-control -model
Select series supplier with prototype tools
Verific. Build-up Certific.run Product release inhouse parts
8. Series suppliers Request for quote… …order placement Tool manufacturing Series supplier
Product release purchased parts Optimization
Requirement specs for manufacturing equipment
10. Production Ramp-up
Request for quotes… …Order placement
9. Production planning
Confirmation run D-samples
Track manufacturing equipment
Ensure parts availability for production tests Optimization and finalization
Installation Start-up approval
Final approval + handover to series production Production Ramp-up tests 1-3
Series production
Daimler Trucks | 10
Responsibilities and reference project organization is derived into 11 subprojects and 32 roles
L TL TM TS TW
1) 3)
Project leader Logistics Integration Material Handling Engineering (MHE) Production Programming & scheduling PPS ISC: International Logistics
TI
IBL: Inbound Logistics
TC
LCM: Launch & Change
TP
PMC: Prod. Mat. Control
TO
OBL: Outbound Logistics
Abbreviation Roles
Abbreviation Roles
Engineering 3)
SQ
Supplier Management
EL
QL
Quality
EI
Integration
QM
Quality Manufacturing
ED
Design
QE
Quality Engineering
EV
Documentation
ML
Manufacturing 3)
EP
Proving/ Testing (entire product, component)
EC
Calculation/ Simulation
EE
Electrics/ Electronics
ES
Styling1)
Prototype build-up
ET
Thermodynamics 2)
PL PE
Purchasing Equipment
PP
Purchasing Parts
MF
Facility Planning
ME
Manufacturing Engineering
MM
MP
Manufacturing in the launch
AS
After Sales
Manufacturing – supply of prototype parts Cost Planning
SM
Sales
FC
Finance & Controlling
MS
Only for truck projects 2) Only for aggregate projects For ML, EL, PL no specific sub-project lead processes are defined, only summary of linked sub-roles
Purchasing 3)
Daimler Trucks | 11
2. P
Abbreviation Roles
Module 1: Concept Project scope and working directions
Project req. spec
Component req. specs
Develop. suppliers pre-selected
9
8
7a
Concept selection Konzeptauswahl
S
10
7
Target positioning and working directions
SM
Compilation technical ideas
ED L
Define project scope and working directions
FC
Set financial target guidelines I to V ED Pre-select technical ideas Investigate concept feasibility entire product Development depth strategy
EI
2. P
Project implem. spec, B-samples available
EI
Description of production network alternatives
MF
ME
Make-or-buy strategy
Define product- und production concept (through Design to Target (DtT) Workshops) Define product- und production concept (through Design to Target (DtT) Workshops)
L
Concept selection Development-depth decision
L
Plant location decision
L
L
Definition
Make-or-buy decision
This module contains all measures and activities necessary for a successful start of the development process and for conceptual decisions. Conversion of customer and market requirements into project goals and working packages. L FC
Project leader Finance & Controlling
EI ED
Integration Design
SM ME
Sales Manufacturing Engineering
Cost Planning
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Module 2: Specification
EI ME FC L L L ED ED
Component req. specs
Develop. suppliers pre-selected
Project implem. spec, B-samples available,
9
8
7a
7
Functional requirement spec entire product contribution to project requirement specification for production planning Project Business Case I to III Project requirement specification Set-up project team for realization phase L Project hand-over Preparation of technical spec for system requirement specs. Technical specifications for component requirement specs.
Project Implementation Spec
2. P
Concept selection
Project req. spec
development supplier offer implementation specs
ED
Decision on styling Concept competitions - LOI
ES PP
Confirm req. spec content for in-house development implem. spec compilation by ext. dev. suppliers
ED ED
Development contracts
PP
Detailing of production concept Finalization of prod. concept ME (for implem. specs)
ME
Definition Within this module all results from the concept phase are documented as requirement and implementation specifications. Contracts with development suppliers are signed. EI ED
Integration Design
PP FC
Purchasing Parts Finance & Controlling
L ES
Project leader Styling
L
ME
Manufacturing Engineering
Daimler Trucks | 13
Module 3: A-samples Project scope and working directions
Component req. specs
9
8
Concept selection
S
10 ED
Project req. spec
Integrate advanced engineering Concept design A-sample components
ED
2. P
EV
Documentation for Simulation A EC
Simulation of components design status A
MP
Review manufacturability design status A Documentation/ Drawing release A-sample
EV
Procurement and delivery of parts & tools A sample
MS
Test A-sample
EP MP
Install design status A-components into mule EP
Test A-sample aggregate carrier
Definition This module assures innovative components and s the selection of competing concepts within the product projects. Synchronization for advanced engineering. A-samples have limited functionality, ready for test bench. ED EV
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
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Module 4: B-samples Component req. specs
Develop. suppliers pre-selected
Project implem. spec, B-samples available,
C-Sample available
9
8
7a
7
6
Design B-sample
ED EV
Documentation for Simulation B Simulation of components design status B
EC
Prototypes for component implem. specs
MP
Review manufacturability design status B
MP
Update design status B Drawing release ‚V‘ B-sample 1)
ED EV
Procurement and delivery of parts & tools B sample
MS
Test B-sample components
EP
Build-up entire-product design status B
MP EP
Install measuring technology (B-sample) EP
Test B-entire-product
Definition This module assures the functionality of components and the entire product. Testing is realized on test bench or in the entire product. Evaluation, whether reliability requirements are provable within the following C-samples. ED EV
1)
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
For Non-MB projects refer to release logic p.77
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
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2. P
Concept selection
Project req. spec
Module 5: C-samples Develop. suppliers pre-selected
Project implem. spec, B-samples available,
C-Sample available
Finalization of LL-tool release
Finalization design
7a
7
6
5
4
Optimize components design status B to design status C
ED EV
Documentation for Simulation C Simulation of components design status C
EC
Review manufacturability design status C
MP
Completion design status C (close to series)
2. P
ED
Drawing release ‚E‘ C-sample 1)
EV MS EP
Procurement and delivery of parts & tools C sample Test C-sample Build-up entire-product design status C
MP EP
Test C-entire-product
Install measuring technology EP
Definition All activities within this module are focused on the assessment of the life-span and reliability of the components and the entire product. C-samples product characteristics mainly fulfill expectations for series production. ED EV
1)
Design Documentation
EC MP
Calculation/ Simulation Prototype build-up
For Non-MB projects refer to release logic p.77
MS EP
Manufacturing – supply of prototype parts Proving/ Testing (entire product, components)
Daimler Trucks | 16
Module 6: D-samples C-Sample available
7
Finalization of LL-tool release
Finalization design
5
4
6
100% customer ready parts, start of prod. tests
3
SOP
Market Launch compl.
2
1
Product reliability
0
Complete 1:1 model - styling freeze ES Final Class-A data Data control model ED Confirm design status D ED Write RfQ documents for future series supplier with development content EV Documentation for Simulation D EI Engineering Release of entire product Simulation design status D EC EP Confirmation D-Components Review manufacturability design status D MP
ES
Finalization design (series)
ED
Drawing release ‚P‘ (series, ordering tools)3)
Finalization development
ED EV
Release of components for pre-production test
Finalization documentation ‚_‘ 3)
EV ED
EV
Documentation for pre-production tests
Release configuration codes ‚V‘/ (preliminary)
EV
EV
Confirm configuration codes 2)
MM Ensure parts availability for pre-tryout („BANF“) TP Build-up entire product in pre-production tests Manufacture D-sample parts ME Confirmation run D-sample entire product EP
Product release (in house parts) QM Customer driving tests 1)
Definition
Certification
EI AS
All activities necessary to achieve series feasibility of the components are described within this module. The actual product has been certified with all components and can be used without any restrictions (released). AS ES ED 1)
After Sales Styling Design
In Japan/India later than SOP
EC EV MP 2)
Calculation/ Simulation Documentation Prototype build-up
Blank Code/Final Code for Non-MB projects
QM ME MM 3)
Quality Manufacturing Manufacturing Engineering Manufacturing in the launch
EI TP EP
Integration PMC: Prod. Mat. Control Proving/ Testing (entire product, components)
For Non-MB projects refer to release logic p.77
Daimler Trucks | 17
2. P
Project implem. spec, B-samples available,
Module 7: Series suppliers for C-samples (only selected parts) Develop. suppliers pre-selected
Project implem. spec, B-samples available,
7a
7
C-Sample available
6 Design components design status C=series 1)
ED
RfQ and assignment of future C=series suppliers with development content (only selected parts)
PP
Drawing release ‚P‘ for C=Series 3)
EV
RFQ and assignment suppliers C=Series
PP
2. P
Track C sample prototype tools 2) Track tool manufacturing (in-house parts) Prepare + select C=series suppliers (prototype tools)
ME
PP
Track C sample prototype tools 2)
Component test C-sample
EP
Definition This module is focusing on those C-sample components, that should be available from series suppliers for C-sample testing. The components can be produced by prototype tools and in special cases also by series tools. ED EV 1) 2)
Design Documentation
PP
Purchasing Parts Cost planning
ME EP
Manufacturing Engineering Proving/ Testing (entire product, components)
3) For Non-MB projects refer to release logic p.77 C=Series: same tools for C-samples and series Responsibility is shared between SQ and specifically for different organization units
Daimler Trucks | 18
Module 8: Series suppliers C-Sample available
Finalization of LL-tool release
5
6
100% customer ready parts, start of prod. tests
Finalization design
4
3
RfQ and assignment of future series suppliers with development content (only selected parts) 1) RfQ and assignment (incl. tools)
PP
Series purchasing contracts
PP
Track tool manufacturing series suppliers 2) D1-components
Optimization of series production tools at series supplier 2)
D2-Components Series preparation at series supplier
SQ
Product release (purchased parts)
SQ
Definition This module includes the activities required to contract series suppliers for series production parts and tools. PP
Purchasing parts
1) Documents 2)
Cost planning
SQ
Supplier management
for RfQs from module D-sample Responsibility is shared between SQ and specifically for different organization units
Daimler Trucks | 19
2. P
PP
Module 9: Production planning Project implem. spec, B-samples available,
C-Sample available
7
6
ME
Finalization of LL-tool release
100% customer ready parts, start of prod. tests
Finalization design
5
4
3
Description and planning of manufacturing equipment Req. specs for manufacturing equipment
ME
PE
Evaluation of implem. specs for manufacturing equipment
ME
2. P
RfQ manufacturing equipment
Order placement manufacturing equipment Track manufacturing equipment
PE
Start PT1
ME
Optimization and finalization of manufacturing equipment Installation, start-up, approval of manufacturing equipment
ME
ME
Definition This module includes the activities required to plan, order and ensure the availability of machines and equipment for the inhouse production. ME
Manufacturing Engineering
PE
Purchasing parts
Daimler Trucks | 20
Module 10: Production ramp-up Finalization design
100% customer ready parts, start of prod. tests
4
3
SOP
Market Launch compl.
Product reliability
2
1
0
Finalization of sales documentation SM
Vehicle configuration for production tests SM Production configuration series/ option Initialize sales order process
SM
Final approval and handover to series production Ensure manufacturability (Complain management.)
ME
2. P
SM
MP
Ensure parts availability for production tests
TP
MM
Production test 1 MM Production test 2 MM Production test 3 Production ramp-up
MM
Series production
MM
Process release (purchased parts)
SQ
Project closure report
L
Definition This module includes the activities required to plan the production ramp-up, to test the production (process flow, quality, tact) and to actual facilitate the market supply within series production. SM MM
Sales Manufacturing in the launch
ME L
Manufacturing Engineering Project leader
SQ TP
Supplier management PMC: Prod. Mat. Control
Daimler Trucks | 21
1.
Overview of quality gate 10 to 0
23
2.
Detailed description on main content of each quality gate
24
2. P
Page
3. Methods
2.2 Quality Gates for truck and aggregate projects (definition, content, responsibility)
1. Overview
2.Product Creation Process (P)
Daimler Trucks | 22
The 12 Quality Gates for truck and aggregate projects following CVDS 3.0 10
9
8
7a
Product finding and definition
7
6
5
4
3
2
1
0
Production Ramp-Up Series production
Product development
Define project scope and working directions Project and concept decision (project requirement specification)
2. P
100% Component requirement specifications Development suppliers are pre-selected Project implementation specification, availability B-sample Availability C-sample Finalization tool release for long lead, C-sample pre-tested Finalization design 100 % customer ready parts / start production tests Start of production (SOP) Market launch completed Product reliability Daimler Trucks | 23
Quality Gate 10: Project scope and working directions 10
9
8
7a
2. P
Definition The project scope is defined. Transparent and measurable working directions for the project are defined. Their definition is based on previous market analysis, competition analysis and predecessors analysis, combined with the strategic requirements of the corporation and adapted to the legal project requirements.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • •
• • • •
Project scope and working directions of all line functions are documented. They are presented to the customer (e.g. PEC) in order for him to take a decision. All necessary resources up to QG9 are available (planning and release of the resources occurs within the FPL framework). Project organization up to QG9 is active since project start. Market analysis and product placement are done ( incl. customer requirements, competitors positioning, required product variations, return and quantitative concept). Gathering of technical ideas starts (Finalization after QG10), potential innovations from pre-development might be integrated at this point. Legal requirements are determined (L and Ex, Qx, SM). Working directions of quality management are defined. Top-Down-Requirements regarding economic efficiency (guidelines) are determined: Working directions concerning profitability, unit costs and resource requirements. Initiation of data collection for the development of product and production concepts (Finalization after QG10) : Competitors components study, data for target cost calculation incl. unit costs of the predecessor's top-parts (if available). Basic costs for predecessor's parts have been handed over to . Basic version of the production network is described. Working directions of the production are available (e.g. optional eHPU Top-Down-Requirements) Working directions of after sales are defined (e.g. maintenance intervals).
L L SM Ex L QL FC
PP MF ME AS
Daimler Trucks | 24
Quality Gate 9: Project requirement spec (project- and concept decision) 9
8
7a
Definition In interdisciplinary teams a technical concept, which realizes the QG10 working directions in the best possible way, has been developed. (Design to Target) The technical feasibility of the product concept, with respect to development (geometry, technique, innovation), production (manufacturability, innovation) and its service capability, has been verified by Ex/Mx . Based on the economic efficiency calculation, project targets, regarding profitability, unit costs and resource requirements, are defined. All sub-projects define their Project Requirement Specifications. Project Requirement Specifications, incl. the schedule framework, are handed over to the series project leader.
7
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • • •
Project requirement specification, incl. project targets / demands of all parts and risk analysis, is available and has been handed out to the series project leader. Initiation of series project after QG9: Series project leader is nominated, project structure and schedule framework, incl. ramp-up strategy, are done. Ex/Mx confirm the product concept (range of development/ innovation, product properties, range of product variety, concept complexity) to be technically feasible and the concept is documented within the product requirement specification. Development depth is defined. Production and logistics strategy (basic manufacturing concept, strategy for the development depth, requirements concerning a production-appropriate product design) are worked out. Pre-selection of the production network is done. QG9´s economic efficiency calculation is based on the most promising configuration. Depending on the project scope, cross-functional Design-to-Target workshops have been organized and completed. Their purpose is to find a concept decision. This concept is documented on component sheets. The economic efficiency calculation is done as new target for the series project ( incl. targets regarding profitability, unit costs and consolidated resource demands). Quality and environmental targets are defined. Selection analysis for D-FMEA has been finalized. A concept for returns, quantitative concept and detailed product requirements (incl. a list of configurations for the reference-vehicles) are available. Purchase strategy, including its contribution to the project profitability, is set up. (Influence of the market environment) After sales strategy, including its contribution to the project profitability, is worked out.
L L Ex
Ex Mx Mx FC Qx SM PP AS
Daimler Trucks | 25
2. P
10
Quality Gate 8: 100% component requirement specifications 10
9
8
7a
2. P
Definition Based on the Project Specification Book and the respective component sheets component sheets, development depth is decided. Detailed requirement specifications for components are worked out in their respective form, depending internal and external development range (Component Requirement Specification). Regarding the external development range, concept competition starts.
7
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • •
Depth of development is decided. Planning of series suppliers for the C-sample, „series suppliers with development scope“, within the component / purchasing schedule. System Component Requirement Specifications and missing Component Requirement Specifications are ready. They are being completed by different contributions of all sub-projects, including estimates on the costs of logistics and driving forces of variation. Start of concept competitions Based on the project requirement specification, design of the B-sample starts. A first factory layout is defined. Market introduction and LCM concepts are further detailed. System FMEA for the product has been carried out. Generation of the production concept initializes. Initiation of risk analysis for development supplier's competition, including component risks. Based on the component requirement specification, target costs are detailed on a final level.
L L All
PP ED MF SM QE ME SQ
Daimler Trucks | 26
Quality Gate 7a: Series development feasibility / development suppliers are pre-selected (LOI) 9
8
7a
Definition There are development suppliers offers for all different levels of quoting requests. Based on this development suppliers are selected by LOI. A first completely documented design status B is available and ready for simulation ( internal and external development). Series development feasibility is proven– the budget to build up functional samples (B-sample) is approved.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • • •
Concept competition completed, offers have been received. Offer evaluation for development suppliers selection is being completed by also considering the subprojects point of view. Development pre-contracts (LOI) are finalized. Component schedule and purchasing schedule are updated. C-Sample components, manufactured by series and prototype tools, are further detailed. Estimations of the HR potential for production are made. Early comparison of targeted per unit costs and the real per unit costs for the entire product. The projects profitability is affirmed. Design status for B components is completed, documented and ready for calculation Based on the merging model (combination of 1:4 models design elements) a styling decision is made. Software for B-sample is implemented and integrated. Test planning has started. Preliminary project implementation specification. Application to release the B-sample purchasing budget
PP All PP L MM FC Ex ES EE EP L
Daimler Trucks | 27
2. P
10
Quality Gate 7: Project implementation specification, availability B-sample 10
9
8
7a
2. P
Definition Implementation specifications of all development ranges fulfill the requirement specification (internal and external developments) and are approved. Design status B is fully documented, analyzed (calculation and producibility analysis) therefore represents the implementation specifications. External development ranges are assigned and contracted (=100% implementation specification for external development). Functional validation starts on component level. Detailed implementation concepts for all subprojects confirm all requirements of the project requirement specification. The implementation specification for the entire project and the implementation concepts are aggregated into the project implementation. Project budget gets approved and the execution of the entire project is authorize.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • •
• • • •
Project Implementation Specification is completed by the Implementation Specification of the entire product and different contributions from each sub-project. Decision over localization and depth of production is made. Requirement Specifications for the different external development ranges are created by the development suppliers. Development contracts are signed. Design-FMEA. Initial status is worked out before a drawing release for the B-Sample is given. All calculations necessary are completed for design status B. Drawing release for B-Sample is given and components have been acquired. B-Sample components are pretested and an assembled B-Sample is ready. The entire product can be tested (function) and software is available. Procurement schedule for internally manufactured C-Sample tools is set up. Production concept is determined up to workstation level. Demand for Production Equipment is described and planned within a time scheduled. Logistics' concept is worked out (contribution to project implementation spec). Comparison between targeted and real costs per unit for the entire product. The project's economic efficiency, based on the Project Implementation Specification and a finalized project budget, is confirmed and approved.
L L ED PP QE EC Ex/ Mx L ME TL FC
Daimler Trucks | 28
Quality Gate 6: Availability C-sample 9
8
7a
Definition Based on the Projects final specification, B-samples are tested relating functionality and integration according the entire product. The from B-sample tests ensure the optimization from design status B to C. This optimized design status is calculated and analyzed for manufacturability. It results in a released design status C for durability testing (near series design status). Components are pre-tested, the CSample entire product is build up, and is available for testing.
6
5
4
3
2
1
0
Overview of main contents • • •
• • • • • • • • • •
*
7
B-Sample testing is completed ( components, entire product) Initial confirmation of fulfillment of Q-targets of B- Sample and C-Components. Components´ and purchasing schedule: - For suppliers for the C-Sample (prototype tools) is set up. - Reachability of evaluation dates, before the start of production, is assured. (backwards scheduling of the part releases „P“) * All design calculations are completed for design status C. C-sample drawing release is available for procurement of components out of prototype tools respective for selected components with C = series tools Manufacturing of the C-sample tools has been accompanied C-sample components are procured and pre-tested C-sample is built-up and ready to the entire product testing Requirement Specifications for production equipment are available. Detailed planning of methods and processes for supplier and material flow controls completed Marketing Confirmation: Price and quantity requirements and product positioning are confirmed Service check with B-sample is finalized, preliminary damage codes are generated Building applications have been placed and building permissions have been granted for all necessary facility constructions.
For Non-MB projects refer to release logic p.77c
EP QE L
EC EV Ex MP ME TP SM AS MF
Daimler Trucks | 29
2. P
10
Quality Gate 5: Finalization tool release for long lead, C-sample pre-tested 10
9
8
7a
2. P
Definition Based on the first results of C-sample entire product testing (durability, rough road, reliability), the design status C is confirmed as a series design status D and released for long lead tools and production equipment. Start of the inquiry process for series suppliers including tools (external production) and production equipment and tools (inhouse production). At this Gate the critical path moves for the release components from the development to the procurement of production equipment and to the assignment of series suppliers. In the case of aggregate projects this gate serves as synchronization point to the target vehicle (pre- tested C-sample aggregate for prototype vehicles delivery date C-sample at Gate 6).
7
6
5
4
3
2
1
0
Overview of main contents • •
• • • • •
C-Samples pre-testing of the entire product is completed (rough road test, overload test usually summer and winter testing) According parts with long lead tools: - D-sample design status has been verified by simulation and manufacturability analysis, - Q-objectives and FMEA measures and validated - parts variety, planning and calculation of series - production tools are proofed. Component and procurement schedule: Preparation for contracting of series suppliers and production equipment suppliers is finalized Planning of production workflow has been updated based on the experience from the C-sample built-up. Risk analysis for production planning: Process FMEA initial position is available The Project efficiency is ensured for the beginning of the series releases. All long lead series tools are fully documented and released.
EP All
L ME QM FC Ex
Daimler Trucks | 30
Quality Gate 4: Finalization design 9
8
7a
Definition The vehicle durability feasibility is proven by a successful completion of the C-sample's entire product tests (endurance test). Design work is completed: According to its lead time, the drawings for design status “series” are released for all machines and tools in order to start the order placements – All Requests for Quotation, for production equipment, are available. Series and production equipment suppliers are hired, according to the component and procurement schedules.
*
7
6
5
4
3
2
1
0
Overview of main contents •
Sufficient C-sample testing entire product confirms the reliability and durability requirements
Results from reliability testing, the design release for all parts. DMU-integration is successfully completed. • For all parts, considering their tool lead time: - Simulation and manufacturability analysis have verified D-sample design status, - Q-objectives are proofed and FMEA measures are validated. - Variety of parts, planning and calculation of series production tools is confirmed. • Design status for series is available. Tool release for all tools is completed (100% “P”)* •
Assignment of series suppliers and production equipment initiated. Product documentation and production program are included into the logistic systems. • Process and equipment spec of logistics is worked out (and deemed to be and of detail planning and basis for implementation) • Finalization of the Requirement Specification for logistic equipment and service suppliers. • Code-release „V“ (preliminary) is started. • •
For Non-MB projects refer to release logic p.77
Ex Qx Ex/ Qx All
ED/ EV Px Tx TL Tx ED
Daimler Trucks | 31
2. P
10
Quality Gate 3: 100 % customer ready parts / start production tests 10
9
8
7a
Definition
2. P
All parts and their series tools are tested and sample part evaluation is finished (100% ISIR (Initial sample inspection report) released for inhouse and purchased parts). Drawings design status “Series“ confirmed – unlimited release of parts for production and after sales (stocking of parts). The production equipment is completely installed, approved, and ready for the start of the production tests. A D-sample was built-up as entire product and the certification has started.
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • • • • • •
*
7
All parts, tools and production equipment are assigned, all purchasing contracts are signed All parts are produced with series tooling and shortly tested The production equipment and tools are completely installed, acceptance and start-up of the production equipment enables the start of tryouts. Progress of process implementation secures the tryouts D-samples are built-up (pre-tryout) Certification has started All in-house and supplied parts are evaluated (product release, ISIR/PPAP) Development is completed and entire product development release is available “_” release for the parts used in production and after sales (stocking of parts for tryouts and start of series production)*. All codes have been ‘_’ (final) released. Prices for vehicles and product configurations series/ option are defined. Finalization of marketing master plan, Products for exhibition purposes are available D-Sample confirmation tests have started. Sales documentation is finalized and approved for PT1
For Non-MB projects refer to release logic p.77
Px All ME Tx MM EI QM/ SQ Ex Ex Ex SM SM EP SM
Daimler Trucks | 32
Quality Gate 2: Start of production (SOP) 9
8
7a
Definition Production tests (tryouts) confirm the capability of the plant to produce products, which are customer ready, without any need for reworks (assembly line completed, quality and tact time). Product and process are released. Homologation for target markets (SOP) is completed. Serviceability for primary target markets is assured. All requirements for the production ramp-up (SOP) are fulfilled. Series production is ready to start.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • • • • •
Production tests are successfully completed: Production workflow verified, product and process release (product audit of entire product) Logistic processes are completely implemented Series-order-process established Finalization of series preparation at suppliers Staff training for series production finished ment for all planned media is prepared and relevant marketing information (commercial and technical) is distributed Homologation is completed and available for target markets (SOP) Serviceability for first target markets (SOP) is assured Production ramp-up is secured Project efficiency is confirmed according to the Project Final Specification, all key figures meet the project targets
Mx/ QM Tx SM SQ MM SM EI AS All FC
Daimler Trucks | 33
2. P
10
Quality Gate 1: End of market launch 10
9
8
7a
2. P
Definition During market launch all Marketing communication measures for the new product are carried out. From SOP on, vehicles are delivered to dealers and selected customers. According to the target markets, serviceability is assured. Production reaches its full capacity rate for the entire product variety. Hand-over to series production is completed.
7
6
5
4
3
2
1
0
Overview of main contents Production reached ridge line during ramp-up. Final acceptance and approval of the production equipment is finished. • Sales documentation is completed and distributed within the sales network. Sales staff training is completed. • For all target markets spare parts availability during market launch is secured. • Series process is verified (entire variety) and continuous improvement process (KAIZEN) is started. • •
Unit cost calculations (based on the updated data of series parts) are finalized and comply with targets. • Customer driving tests have been evaluated. • Hand-over to line organization is completed. •
MM ME SM AS ME/ MM FC AS L
Daimler Trucks | 34
Quality Gate 0: Product reliability 9
8
7a
Definition The product reliability is analyzed and evaluated. Measurements to optimize the product are determined. Commitments documented in the project specification and respectively specifications of all subprojects are verified within the final project report. The project leader and the project team are discharged.
7
6
5
4
3
2
1
0
Overview of main contents • • • • • • •
All final acceptances of equipment have been carried out with positive results. Confirmation run of D-sample entire product to prove reliability is completed. Profitability of the entire product is calculated according to F&C standards Lessons Learned are documented. Final quality report is prepared: Long term capability of production processes is proofed. Product audit within series process is accomplished. Based on the final consolidated economical evaluation the project economic efficiency is confirmed. All key figures meet the projects targets. Final project report is completed.
ME Ex FC All QL/ QM FC L
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2. P
10
1. Overview
2. Product creation process (P)
2.3 Main content/ roles and their tasks over time 32 Roles – one page per role
37
3. Methods
2. P
1.
Page
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Main role content of Project Leader (L) Main topics
FPL Concept and specification
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Working directions QFD Concept selection Legal requirements Align project org. with concept decision + handover to project QG10 leader chapters Proj. implementation specs Proj. requirement specs
Handover to series Final project report
req. specs
Changemanagement
implem. specs B-sample
C-sample
Invest
Releases
C=series tools payments
Assign development suppliers for development Location/ Integration
Time schedules
Make or buy
Start Time sensitive Matrix components
Invest series tools + manufac. equip. Internal contracts
Development depth Strategy Decision Strategy
D-sample
Legal framework
Series
Final payments for manufacturing equipment for supply
Location Decision
Series suppl. for for C-sample B-sample
Series for suppl. w/ C-sample dev. costs
Ensuring Ensuring tool awarding lead time phase
Further topics: Project synchronization (aggregate – vehicle)
Component/procurement scheduling PM
Detailing Planning/ Working Set-up Project order
Stabilization PM
Verification project order
Project Closing Project steering
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2. P
Analysis of project complexity + initiation of risk management
Main role content of Logistics Integration (TL) Main topics
S
10
Concept selection
Logistic Strategy
Frontloading
9
8
7a
7
Logistic Concept
6
5
4
Detailed Planning
3
2
1
Implementation
Contrib. to location decision Predecessor analysis
2. P
Strategy
Logistics costs
Assessment of supplier quotes
Logistics costs
Specification process
of development suppliers
Costs for creation of scenarios
Costs & funding for business case
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=series suppliers
Target costs logistics
Contrib. to Project implementation spec
of series suppliers
Continuous reporting target- vs. EA-costs
Process & equipment spec
Operation manuals
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0
Main role content of MHE: Material handling engineering (TM)
Location
S
10
Concept selection
9
8
Logistic Strategy Contrib. to location decision
Material flow
Selection of basic delivery modes
7a
7
6
Logistic Concept
5
4
Detailed Planning
Concept of material provision and delivery modes
3
2
1
Implementation
Production tests
Detailed planning of material flow processes
SOP
Implementation of material flow processes Carrier/ container Conception
PTs
Determination
Planning
SOP
Provision Final coordination of packaging with suppliers
Carrier & equipment
Planning of logistics equipment Req. specs for logistics equipment Procurement of logistics equipment Buildup, startup, approval
Area
Assessment of supplier quotes
Specification process
0
Requirements for area (Business case)
Verification & rough layout
Detailed planning
Area allocation plan Area allocation
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
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2. PEP
Main topics
Main role content of Production programming & scheduling (TS) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept
4
Detailed Planning
Definition of methods
Process Planning & Implementation
5
3
2
1
Implementation
Detailed planning
Coordination of planning restrictions Analysis Specification
Implementation & Verification
Securing IT
2. PEP
Calculation of parts demand Initialization / Implementation
Production program
Creation of production program on level „model range“ Creation of production program on level configured products e.g. model, code
Parts demand
for Production Tests for Start of Production
Specification process
Contrib. to Project requirement spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
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0
Main role content of ISC: International logistics (TW) Main topics
S
10
Concept selection
9
Logistic Strategy
8
7a
7
6
Logistic Concept
5
4
Detailed Planning
3
2
1
0
Implementation
Definition of basic supply chain scenarios Concepts & Processes for Internat. supply
Assessment of supplier quotes
Specification process
Determination of internat. supply concepts
Rough concept internat. supply
Detailed planning
Verification
1st Shipment PTs Series EDI ready Implementation of Series processes
Data collection Requirement specs for service providers internat. supply
Coordination of IT-Concepts Inquiry of new transportation concepts & relations
Contracting
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
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2. PEP
Contrib. to Location location decision planning
Main role content of Inbound logistics (TI) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept
5
4
Detailed Planning
3
2
1
Implementation
2. PEP
Contrib. to Location location decision planning
Definition of basic transportation concepts Concepts & processes for Transportation
Determination of transportation concepts
Detailed Planning of transportation concepts
Production tests Series Implementation of series processes
Inquiry of new transportation concepts & relations Requirement specs for service providers Contracting
Assessment of supplier quotes
Specification process
Logistics costs of development suppliers
Contrib. to Project requirement spec
Contrib. to component req. spec
of C=Series suppliers
Contrib. to Project implementation spec
of series suppliers
Contrib. to Process & equipment spec
Operation manuals
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0
Main role content of LCM: Launch & Change (TC) Main topics
S
10
Concept selection
Logistic Strategy Process Planning & Implemen -tation
9
8
7a
7
6
Logistic Concept Definition of methods
5
4
Detailed Planning
2
1
0
Implementation Initialization / Implementation
Detailed planning
Analysis
3
Specification
Prod.docs input
Implementation
Consistency testing D-Sample 18 15 12 9 6
Documentation
Update (based on ‚_‘) Check for crit. types Production tests SOP
Scheduling & Ramp up planning
Specification process
Scheduling
For complete product range
Contrib. to Project requirement spec
Ramp up planning
Contrib. to Project implementation spec
Update
Contrib. to Process & equipment spec
Detailing Ramp up scenario
Operation manuals
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2. PEP
Securing IT
Main role content of PMC: Prod. Mat. Control (TP) Main topics
S
10
Concept selection
Logistic Strategy
9
8
7a
7
6
Logistic Concept Concepts for material flow control
5
4
Detailed Planning
3
2
1
Implementation
Detailed planning of methods/processes
Production tests SOP
Material Flow Control
Implementation of internal material flow control Securing IT
2. PEP
Detailed planning of methods/processes for supplier control
Implementation of Processes for supplier control Verification of inventory planning for purchased parts (required storage area)
Supplier Control
Parts availability for pre-tryout (BANF) Call off orders for ISIR parts Parts availability production tests Parts availability for Ramp-Up
Specification process
Contrib. to Project requirement spec
Contrib. to component req. spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
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0
Main role content of OBL: Outbound logistics (TO) S
10
Concept selection
9
Logistic Strategy Location planning
8
7a
7
Logistic Concept
6
5
4
Detailed Planning
3
2
1
0
Implementation
Contrib. to location decision Definition of basic transportation concepts
Determination of transportation concepts
Detailed planning for particular markets
Production tests Series Implementation of Series processes
Inquiry of new transportation concepts & relations Concepts & processes for Transportation
Space requirements for shipping Estimation Detailed planning Virtual loading test
Physical loading test Requirement specs for service providers Contracting
Specification process
Contrib. to Project requirement spec
Contrib. to Project implementation spec
Contrib. to Process & equipment spec
Operation manuals
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2. PEP
Main topics
Main role content of After sales (AS) Main topics
Concept Specification
S
10
Concept selection
9
Proj. req. specs Concept AS working directions
8
7a
Contribution
7
6
5
4
3
2
1
0
Proj. implem. specs Ensuring part exclusiveness (for series awarding)
Verification in component implementation specs
Integration AS requirements in comp. requirement specs
2. P
Service Checks
Service Check secure serviceability work values/prices for W&P with A-sample
Diagnosis
Repair
Concept
Methods Customer driving tests *)
with B-Sample
Definition concept + req. repair center
with C-sample
Basic diagnosis Planning … Data input
with D-sample Development „Guided search for errors“
Deliver to repair center
Verification ‘flashing’
Market preparation and infor -mation
Plan: Training + service concepts
Marketing framework and training plan
Qualif. service network Preparation Service network Repair center info Document.
Procurement of spare parts
Verification AS Launch Check Standard languages Publication
Ramp-up process Concept spare parts (inhouse)
Spare part definition and bill of material
*) Customer driving tests in some countries (e.g. Japan + India) only permitted after SOP and with homologation
Check prod. reliability field
Basic availability Procurement
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Main role content of Sales (SM) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Market req. and competitors Product/ SM working directions product Quantities + revenues positioning Product portfolio Product positioning
Specification
Verification product req. change management product config.
Consolidation product req. product config.
Proj. req. specs
Contribution
Comp. req. specs
2. P
Product concept w/ series + options
Proj. implem. specs From development
Comp. implem. specs
created „V“ Code restrictions
Detailing of product requirements
Released „_“ Start of sales SOS
Concept Market launch
Ramp-up planning
Validation of quantities
Final.
Marketing framework
Vendor training
Events
Prepare media presentations Process and system adaptations
Market launch and lifecycle concept
Marketing documentation
Documentation prices Vehicle configuration Creation Centr.
Market Initialize sales order process
National Vehicle configurations Defines for prod.tests reasonability check national market launches
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Main role content of Supplier management (SQ) Main topics
Specification
S
10
Concept selection
9
Contrib. proj.req.specs
8
7a
7
6
5
4
3
2
1
Contrib. proj.implem.specs
for comp. req. specs Development suppliers B-Sample
2. P
C-Sample Control suppliers
18 15 12
9
6
D-Sample Series suppliers C=Series suppliers
for C=Series suppliers
Preparation for series
for series suppliers.
in preparing documents for RfQ Selection: suppliers Development suppliers.
C=series suppliers.
Series suppliers
Risk analysis Planning Prod. and processrelease
Evaluation C=Series tools
Product release *) Process release Long-term capability
*) ISIR / PPR: Product „green“ and process „min. yellow“
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0
Main role content of Quality (QL) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Specification Q-Plan Concept phase
Working directions
Project targets from quality and legal req.
Quantification Confirm. for proj. implem. specs
Engineering release of entire product
Confirm consistent Q-objectives in comp. req. specs Concept validation
2. P
Specification for proj. req. specs
Setup time line for product audits
Finalize concept audit B-Sample
Confirm Q-objectives for entire product (based on comp.implem.specs)
100% finalization development („_“) 100% finalization design („P“)
Product and process release
Verification long-term capability
Release product development
Project audit for B-sample phase for C-sample phase Q-reports
for D-sample phase Final Q-report
*) carried out by plant quality dep. (QM-role)
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Main role content of Quality manufacturing (QM) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Weak point analysis of predecessor Concept phase
Concept analysis evaluation Contrib. proj.req.specs
2. P
Q-Targets
Contrib. proj.implem.specs
Detailed QM plan for manufacturing
Detailing quality objectives for manufacturing
Implement into concept selection .First scope definition Process FMEA
Updating and activity monitoring Update of scope
Initial status
for C=series tools feasibility of safety relevant characteristics (for „P“-release) Q-control loops1..5
Planning Implementation Testing Verification efficiency Product audit
Implementation
C-Sample
PPR-inhouse parts
Pre-tryout
PPR-entire product 2) PPR: Product and process release entire product
Prod.test
Series
Product release1) Planning Process release
Verification process capability
1) ISIR / PPR: Product „green“ and process „min. yellow“
Capability of test devices.
Short-term
Long-term 2)
Planning
Impl.
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Main content of the role Quality Engineering (QE) Main topics
S
10
Conceptselection
9
8
7a
7
6
5
4
3
2
1
0
Analyze predecessor product
Reliability / Durability
Evaluate concepts from QE view Validate Quality for: engineering release design release of entire product
Input to QE targets Input proj. req. spec Define targets for entire product
Input proj. final impl. spec
Evaluate test planning B-sample
Monitoring endurance testing according to the test planning C-sample D-sample
Define targets for components Monitoring B-sample
W&P
Estimate W&P rates for concepts
ZEUS
Define targets for entire product
Issue Tracking
D-sample
Statement about reachability2)
Statement about sufficient confirmation2)
Statement about confirmation2)
B-sample
C-sample
D-sample
Notes to Simulation, Test planning, Design
Select components for FMEA FMEA
C-sample
W&P planning
Start FMEA comp. System-FMEA entire product
FMEA-updating and activity monitoring
Validate FMEA measures
Safety Identification Confirmation and Documentation relevant Parts (DS) 1) Coordinated by the QL role 2) Statements about Reliability, Durability and W&P serve as for Development
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2. PEP
Concept Specification 1)
Main role content of Facility planning (MF) Main topics
S
10
Concept selection
9
8
Initial situation Description
7a
7
6
5
4
3
2
1
Conception
Production network
2. P
Pre-selection
Plant layout
Determination Plant location decision
Rough
Detailed Specification
Plan realization of constructions (contrib. implem.specs)
Realization
Time period for approval
Evaluation of basic information Concept planning Detailed planning Building application File the building application and approval Production planning
Application approved
Documents for RfQ RfQ phase Awarding Implementation planning
The entire part “Realization” has to be synchronized with the delivery of machinery and equipment
Approval Transfer of risks Ready for occupancy Implementation plan Realization
Remedy of defects Documentation
Date for building application: a) calculated by backward scheduling b) Time to permission + construction duration highly dependent on location
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0
Main role content of Manufacturing Engineering (ME) S
10
Concept selection
9
8
Strategy
Make or buy
Concept
Detailing
7a
Decision
6
5
4
3
Release of investment
18 15 12
9
0
D1 D2 Manufacture D-sample parts
Assessment of quotes Track manufacturing Manufacturing equipment 2 C=Series TQG-1
Start-up Approval
TQG-0
Production work flow
Structure
Detailed planning
A-sample
Concept selection
B-sample
SOP Hand-over
Integration experiences Finalization C-Sample (Base for final Styling)
Interfaces (develop.)
1
6
Req. specs for manufacturing equipment
Production technologies Innovat. Verification of feasibility
Process laboratories
2
1
Contrib. proj. implem. specs.
Production alternatives
Production processes
7
2. P
Main topics
Verification
Start Kaizen
C-sample
Assessment of implem. specs of development
1 Make or buy decision is coordinated by „FC“ role
2 Special process: only applies for in house parts with C= series tools
TQG: Technology-QG: 1 Concept Suitability, 0 Applicable Technology
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Main role content of Manufacturing in the launch (MM) Main topics
2. P
Concept
Planning staff requirements
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Requirements for staff
Evaluation of staff potential Update evaluation of staff potential
Planning of staff requirements Content and requirements for training concept
Recruit staff Recruit staff
Negotiation of company agreements
Training of staff
Staff ready
Staff for prototype manufacturing Staff training Staff training
Extended staff training (rotation and substitute) D1 D2 Manufacturing D-sample parts 1 2 3 Prod.tests
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Main role content of Prototype build-up (MP)
Feasibility studies
S
10
Concept selection
9
8
For concept selection
7a
7
6
5
4
3
2
1
0
Produceability assessment of implem. specs
Securing comp. req. specs
design
Review manufacturability1)
18 15 12 9
6
Review manufacturability Verification of review manufacturability
2. P
Main topics
Ensure manufacturability in pre-tryout
Series preparation
Prod.tests Series Complain management Planning Build-up components
Prototype build-up
Production data for lines
Build-up entire product
Training of disseminators Testing parts from C=series tools
A-sample
B-sample
C-sample
Ramp-Up
D-sample Coordination & Complain management
PT1 PT2 PT3 Ramp-Up Series
1)
Review manufacturability: e.g. drivers cab (Interior/Exterior „Cubing“) chassis or aggregate first in digital form (DMU) afterwards physically (PMU) confirmed
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Main role content of Supply of prototype parts (MS) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
2. P
Scheduling
Prepare procurement
Product documentation Procurement parts a. tools
Hand over to series
Hand over to series logistics
A-sample
B-sample
C-sample
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0
Main role content of Cost planning () Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Specification target costs components Moderation product/production concept
D-Sample
Predecessor competitors (reference calculation) Top parts Pre-selection Component Assessment LOI implem.specs Target costs in comp.req.specs Assessment of quotes Contrib. proj. req. specs. Contribution proj.implem.specs
Plan Complexity Mgnt.
Cost assessment of changes C-Sample
B-Sample
Analysis
B-Sample
2. P
Product and productionconcepts (Design to Target) and cost calculation
Verification/ monitoring / confirmation C-Sample D-Sample
Organizational association has to be specified for the projects
Optimization of quotes Confirm. for proj.implem.specs
Funding
Target costs series tools for comp. req. specs
Tool cost optim./change assessment/ calculation B-sample C-sample D-sample 18 15 12 LOI
Tool Mgnt. 1)
Evaluate and confirm tool runtime
B-sample External development
6
Assess quotes from develop. suppl. Planning budget for series tools: Planed disposed funded Track tool manufacturing. 2)
1)
9
Comp. implem.specs
2)
C-sample
Within German aggregate plants „supplier management“ (role SQ) is responsible
D1 D2 Tool opti.2) Series
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Main role content of Finance & Controlling (FC) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
Financial target guidelines
0
Final assessment of entire product in project closure report Validation prototype costs
Break down of working directions
B-sample Product- and production concepts
2. P
Definition of Target costs (Product)
1
C-sample
D-sample
Production Development location/ depth MoB-decision
Transition of project to series calculation
Financial evaluation/ Business case Determination and tracking of market and transfer prices Contribution for req. specs.
Project Profitability
Contribution for implem. specs.
Update project business case for each gate EA1)
Tracking target costs based on unit cost calculations for each gate EA1)
Cost approach (symbolic) Open project s
Confirmed in proj. req. specs for Budget Top down targets project order (Project) Funding for project req. specs
1)
Close project s
Finalized in proj. implem. specs for project implementation
Funding for B-sample and project implem. specs
EA = „Expected Actual“ that is comparison of status and target
Update funding and compare with periodical planning for each gate EA1) Funding for C-sample
until QG 0 Funding for series tools
Controlling and tracking of ramp-up costs
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Main role content of Integration (EI) Main topics
S
10
Concept selection
9
8
Product req. specs
7
6
Confirm. req. specs= implem. specs
Comp. req. specs Specification
7a
Comp. implem. specs
Integration advance development Strategy Decision
5
4
3
2
1
0
Level of entire product
Integration of component level Engineering Release of entire product
Development depth
Concept analysis
Configuration entire product
Validation design
A-sample
B-sample
C-sample
2. P
Concept selection (DtT)
D-sample for pre-tryout
for prod. tests
Prev. to calculation 18 15 12
9
6
Prev. to procurement Design status on sample Characteristics Mgnt. 1)
Definition of requests Installation/ Build-up 1)
Analysis Assembly/ Body manufacturer
Validation Assembly/ Body manufacturer
Verification Assembly/ Body manufacturer Certification run
Define product characteristics
Homologation
Until „_“- release
B-sample
D-sample C-sample
„Sign-off“-Process for vehicle use at body manufacturer or use of aggregates at external supplier
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Main role content of Design (ED) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Principal feasibility Specification
Concept selection (DtT)
2. P
External
implem. specs for ext. development
Component req. specs
Confirmation req. specs in house develop. (implem. specs.)
Series supplier w/ development content *) Finalization design 18 15 12 9 6
C=series tools („P“) Design
2)
*) Cooperation with series suppliers with own development by paying development costs (collaboration until ‘P’-release). Development scope is specified and documented in component/procurement schedule, before QG8 (if necessary: special processes can be added)
2)
Finalization development
Specific. „V“
Change management Components
Analyze testing results
Components
Entire product
A-sample
B-sample
Release „_“
Configuration codes
Components
Entire product
C-sample
Entire product
D-sample
Interfaces (cooperation) Comp./procurement schedule1)
Develop. suppl. (for req. specs) + basic list all components/ parts
Series supplier with C=series tools
C=series supplier with prototype tools
Preparation series suppliers
1) Component/ procurement schedule are specified by project lead in cooperation with purchasing and development department. If necessary, additional departments (e.g. suppliers management) are involved. 2) Simulation (Role EC) + review manufacturability (role MP)
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0
Main role content of Documentation (EV) S
10
Concept selection
A-sample Build up BoM
Build up frame for BoM
9
8
7a
7
6
C-sample
B-sample
4
2
1
„V“
5)
3)
1)
‚V‘
7) 4)
Awarding series supplier and series tools ‚P‘
C=series tools Initial stage Product configuration
15 12 9 (‚P‘)
6 6)
Documentation Configuration codes
„_“
6
‚E‘ 2)
b (‚_‘)
a
‚_‘-Release „w/o restrictions“
c b
c
a Parts without required tests:
‚_‘ release after final clarification with suppliers
For MB-vehicles 1) ZS-B 2) Z1-Z5 for B-sample 3) ZS-C 4) Z1-Z5 for C-sample 5) ZS-D 6) F2-F5 for special cases 7) F1-F5 regular
0
BoM for pre-tryout
18 15 12 9
Document. for procurement
3
D-sample
Reference BoM
Document. for simulation
5
b
Parts with required tests: ‚_‘ release after short test of part from series production tool
c Then finalization of ISIR until Gate 3 BoM = Bill of material
(done by suppliers mgmt (role SQ) Next: Release for production
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2. P
Main topics
Main role content of Testing (EP) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Assessment innovations and concept
General
Def. Requirements from testing concept selection (DtT)
2. P
Proj. req. specs
Ensuring/ evaluation req. specs. Comp. req. specs. Req. for prototype tests Ensuring test rigs
Test plan
General test plan (DVP&R)
For B-sample
For C-sample
For D-sample
from prototype tools
Comp. tests
Optional for „-“ release
C=series tools Install measuring technology Tests entire product
Acc. testing. (Optional)
A-sample
B-sample
Acc. testing.
C-sample
Certification Customer driving tests
D-sample Daimler Trucks | 62
0
Main role content of Calculation (EC) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
0
Principal feasibility
General simulation
Concept selection (DtT)
Components
2. P
Req. specs
Entire product Implem. specs
Simulation Components
18 15 12
9
6
Verification attending to comp. testing
Simulation
Ensuring Certification
entire product
Attending change mgnt. from D-sample tests Verification attending to entire prod. testing
A-sample
B-sample
C-sample
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Main role content of Electrics/Electronics (EE) Main topics
S
Concept selection
10
9
8
7a
7
6
5
4
3
2
1
Principle feasibility Concept selection Specification
Integration advance development Project req. specs.
Project implem. specs.
Component Req. specs Implem. specs.
2. P
External
Contribution
B-sample
Specific. „V“
C-sample C=series tools („P“) *
*
Simulation
Hardware
D-sample Finalization design 18 15 12 9 6
Simulation
Release „_“
Configuration codes
Finalization development
Package space validation Testing Homologation samples Production tests SOP
Integration diagnostic concept Requirement specification Comm.matrix. Overlapping synchronization
SWIntegration
Software is ready for…
4
SWcomp.
2
Concept
1
Final Release Test
3
1
Specification 2
Specification
Implementation 3 Integration 4 Application/Test
Last bug fixing Test for final release
incl. summer/winter test
*
Simulation is carried out in role EC
Daimler Trucks | 64
0
Main role content of Styling (ES) S
Main topics
Concept selection
10
9
8
7a
7
6
Market trends Concepts
Pre-selection
Color
5
4
3
2
1
0
Decision
Sketches 1:1 Prop. 1:4 CM1) Selection CM1) Styling Exterior
Models StylingFreeze2)
Styling freeze Management release
2. P
Styling decision
B-sample
Data contr. model „Class-A Data“
for C=Series tools C-sample
DCM2 DCM1 DCM final Series
Market trends Sketches
1:1 Prop. Selection CM1)
Styling Interior
Models Concepts
1)
CM: Consolidated model
2)
Pre-Selection
Color
Only in case of C=Series tools, which have influence on Styling
Decision
Daimler Trucks | 65
Main role content of Thermodynamics (ET) Main topics
Req. and impl. specs.
2. P
Design components
S
Concept selection
10
9
8
7a
7
6
5
4
3
2
1
Contrib. Proj. requirement specs Components Req. specs. Implem. specs.
A
B
C
Finalization release
Principle feasibility Concept
Concept selection
Detailed concept for vehicle specific variants
Detailing
Data performance maps
Data set
Def. u. decision of requirements for tests and test rigs Application Test
at 1-cylinder
Detailed optimization engine – vehicle. on rig test (B50) Engine/aggr.carrier (C20 - C50)
Sys.integration
A-sample
in aggr.carrier (B100)
B-sample
Data for flashing on line
Validation in certification run
in target vehicle (C100)
C-sample
D-sample Daimler Trucks | 66
0
Main role content of Purchasing Equipment (PE) Main topics
Specification
S
10
Concept selection
9
8
Forecast for proj. seq. specs.
7a
7
6
5
4
3
2
1
0
Confirmation for proj. implem. specs.
Budget planning
External development partners
Building contractors
Logistics service providers
2. P
Further awardings
„P“-releases from development
18 15 12 Suppliers for manufac. Equipment
9 6
RfQ for manufacturing equipment suppliers 18 15 12
Assessment quotes / awarding
Series tools. C=series tools
9 6
Regular awarding
Interfaces (cooperation)
Comp./ procurem. schedules
Planning C=series tools In house parts
Preparation RfQ for manufacturing equipment
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Main role content of Purchasing parts (PP) Main topics
S
10
Concept selection
9
8
7a
7
6
5
4
3
2
1
Procurement strategies on supplier base Strategy
Assessment of market environment (DtT) Contribution for Req. specs Concept competitions
Develop. suppliers Specification
*) Cooperation with series suppliers with own development by paying development costs (collaboration until ‘P’-release). Development scope is specified and documented in component/procurement schedule, before QG8 (if necessary: special processes can be added) see role ED
Series supplier with development content *)
Development contracts
2. PEP
„P“-releases from development here „E“-release
18 15 12
9 6
RfQs with drawings Series suppliers2)
18 15 12
Assessment of offers and series assignments If necessary further negotiations Series tools Prototype tools Process for C=series suppliers
9 6
Series purchasing contracts Purchasing contracts for after sales
Regular series awarding
Interfaces (cooperation) Comp./ procurem. schedules 1)
Develop. suppl. (for req. specs) + basic list all components/ parts
Series supplier with C=series tools
C=series supplier with prototype tools
Preparation series suppliers
1)
Component/ procurement schedule are specified by project lead in cooperation with purchasing and development department. If necessary, additional departments (e.g. suppliers management) are involved.
2)
Series assignments (LON) LATER tooling process is started. Further negotiations will be set up together with cost planning (role )
Daimler Trucks | 68
0
1.
Time critical path
70
2.
Integration and innovation
71
3.
Specification process
72
4.
Sample logic
73
5.
Supplier decision and tools for C-Sample
75
6.
Releases along the Samples
76
7.
Maturity level logic
77
8.
Releases: Requirements and consequences
78
9.
Tool process
79
10.
Important milestones of the process chain
80
11.
Phase of production tests
81
12.
Ramp-up methods
82
13.
Synchronization of truck and aggregate with an example
83
2. P
Page
3. Methods
2.4 Main topics and detailing
1. Overview
2. Product creation process (P)
Daimler Trucks | 69
Time critical path in the product creation process Project scope Project and Series B-Sample and Concept decision Comp.req. suppl. available, working directions (Proj. req. spec.) specs pre-selected Proj.implem.spec
10
9
8
7a
C-Sample available
7
6
100% Finalization customer ready parts Market launch Product Design start of prod.tests SOP completed reliability
Finalization of LL tool release
5
4
3
2
1
S
Product finding and -definition
Proj. req. Project impl.specs specs Product Production concept Prod. req. Sys.+Comp req. Sys.+comp. implem. specs. specs. specs. Production. Detailing production concept req. specs. Styling contracts decision Dev. suppl. 1:4 Models 1:1 Models Packaging/DMU-verification
Productdevelopment
Concept design A Analysis ASample
Test A-Sample
Finalization Design
DCM-Class-A
V / EB
E / EC
Optimization B C Analysis C-Sample Release C
Design status B Analysis B-Sample Release B
Comp.test
Styling freeze
Component test Assembly
Long lead
Test B Sample
Required confirmation…. Short lead Not necessary needed “_” P/A
Verification CD Verification of certification Release logistics
Series release D
Component test Assembly
Accelerated test
Release Product configuration Test C Sample
Test for product release
Cert. run
Series suppliers with proto. tooling
Test D-Sample
Product release in-house parts
Series suppliers with C ≙ series tooling1)
Tool ordering
Ramp-up/ Series prod.
2. P
Work. dir.
Process capability
Tool making Approval of manufacturing equipment
PT1 PT2 PT3
Series production
V / EB
Time critical path
DCM=Data Control Model PT=Production test
Releases: MB Trucks + Fuso/ DTNA
1) Only selected parts
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0
Integration of Innovations into the product creation process Innovation creation (component)
Idea generation
IQG2
Preliminary study Definition of target product/ segment
Productcreation
Long term time scheduling
Functional Proof
Integration Suitability within target project
•
IQG0
IQG1
Innovation project
•
Future Projects input of Advanced Engineering
Hand-over of mature innovations to product creation process
Confirmed List of Future Projects
10
9
Securing : •
Technical suitability of the component for the target product
•
Component maturity is assured (technically and economically)
•
Consideration of marketing and production requirements of components
•
Compliance with legal aspects
Optimizing: •
Steering of innovation projects
•
Responsibilities of technologies, developed by advanced engineering, are transferred to series development (Product projects)
Concept selection
Synchronization: • At gate “9“ and “concept selection“, the corresponding contributions will be assured by Advanced Engineering and triggered by Product Planning • Target for IQG 0: no later than “concept selection“, if possible to gate “10“. Hand-over points for concept relevant innovations; hand-over for other innovations can be later
Daimler Trucks | 71
2. P
IQG3
Project Maturity
S
Innovation Draft
Objectives of Innovation QG
Specification process 10
9
Level
Project
Sub-chapters
2. P
Entire product
8
7a
7
Requirements Working directions
4)
Systems
Components
Production (exemplary for following sub-projects)
Project req.
Properties of the entire product
Confirmed implem. spec of entire product
Entire product req. specs
Workshops concerning product and production concept (DtTWorkshops)
Production concept
Project implem. spec 2), 3)
spec1),3)
System req. specs
Req. Specs. Production (craft level)
System implem. specs.
Offers (External development) Component req.Design specs (Internal development)
Component implem. specs.
Production concept on work station level
Approval 1) Requirement Specification: Defines “ what“ the product is expected fulfill Requirement specification, order 2) Implementation Specification: Defines „how“ the requirements will be fulfilled Commitment against customer 3) Project req./implem. Specs. : Aggregates, besides the product information, all sub-project contributions 4) Entire product: Equivalent to project scope, i.e. truck, engine, axle, transmission etc. depending
Daimler Trucks | 72
Sample logic: Definition A-/ B-sample B-sample
Manufacturing
•
Made by prototype tools or hand-made (not necessarily made out of target material)
•
Made by prototype tools (not necessarily made out of target materials)
Application
•
Functional and independent component tests without environmental conditions (within the aggregate carrier also possible)
•
Installation tests and functional tests are carried out on the test rig, e.g. within entire aggregate or vehicle.
Objectives
•
Assurance of innovations (conclusion of advanced development)
•
Management of the decision on alternative, competing product concepts
•
Existing requirements regarding functionality and envelope space have to be fulfilled (perspective: Requirement specification). Requirements should also be evaluated with respect to the component (life time / durability capability is not focused)
•
2. P
A-sample
Confirm: Function Forecast: Reliability Function, geometry, surface, connection technique, haptics, mechanical and electric requirements, temperature tests, basic durability etc. have to ensure future characteristics of the series product (suppliers have to show all derivations)
•
Initial cost analysis on parts level is available
•
Initial status of the FMEA is considered.
•
Basis for make or buy decision and the production concept.
Daimler Trucks | 73
Sample logic: Definition C-/ D-sample D-sample
Manufacturing
•
Functionality and product properties are similar to series: Fine-geometry (radiuses, form, grain…) and used materials are very close to series (not necessarily made with series tools) • Principle of manufacturing: Master-forming and shaping are close to series ( not necessarily made with series tools)
• • •
Application
• •
Reliability tests on (overload)-test rig Tests with first target vehicle
•
Objectives
•
Assure installation, functionality, properties, endurance and reliability. Surface quality is close to series. Envelope space requirements and the positioning of points meet assembly requirements. Reach drawing geometry “Series“. Assure a maturity so that production equipment can be ordered. Ensure that tools are manufactured
2. P
C-sample
• • • •
Design with series-production status Produced out of series material with series tools Products to be built within pre-tryout / production tests • D1-sample: first parts from series production tool with series geometry and materials, which were manufactured under close to series conditions • D2-sample: as D1, but produced under full series conditions.
Examination of all factors, relevant to the product.
• •
Suppliers have to complete all quality-relevant tests D1: Last confirmation though development, type testing, pilot series (pre-tryout), Homologation • D2: Proof that part is conform to series documentation (part successfully sampled (ISIR), maturity for production tests/tryouts is obtained.
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Supplier decision and tooling for C-sample Development
In-house Development Scope
Supplier
Prototype Tool
Series tool
Development Supplier
If contracted with LOI or development and supply contract
If necessary 1)
Design Status close to series3)
Series Assignment
Supplier Prototype Supplier
Standard 2)
Series Supplier
If competence of supplier important for C-Sample and know-how has to be transferred to series
Series tool
Final Design Status 3)
If a development supplier cannot deliver prototype parts
If necessary1) Final Design Status 3) Series Assignment
Design Status close to series 3)
2. P
No changes of contract Prototype Supplier
Prototype Tool
One-time Assignment, no Series Assignment (internal determination)
One-time Assignment
1)
Coordinated and defined by Project Lead in the Procurement Schedule at Gate 8 Issues according Safety and Quality Engineering and Quality, Issues according Costs Cost Planning, if necessary Purchasing
2)
Forward Looking necessary on part Level: If supplier change from C- to D-sample doesn‘t jeopardize the SOP. Parts have to be available for certification and sample parts evaluation in the demanded Quality.
3)
For MB-Trucks: close to series corresponds to E-Releases – Final Design Status corresponds to „P“-Release
Daimler Trucks | 75
Releases are granted with the samples 10
9
8
7a
7
6
5
4
2
1
0
100% parts „_“
100% parts „E“
S
100% parts „V“
3
Engineering release of entire product
100% ISIR Concept A
Design
2. P
Analysis
Manufact.bility simulation
Drawing release
Design B-sample components
Analysis A-sample
A-sample IQG 0 Components
Testing Entire product
Optimize BC Analysis B-sample Release B
Comp.test Test A-sample
Analysis C-samples
C-sample
B-sample Series suppliers for C-Sample (only selected parts)
Simulation/ review manufac.bility
Release C
Component test Buildup
D-sample
Confirm CD
„P“
Release D (Finalize design)
Component tests
Test B-samples
Buildup
Accelerated test
Finalize Docs. Confirmation
Test C-samples
Build-up Confirm. Cert.run
Confirmation run D-samples
Delivery D1 Series supplier with prototype tools Series supplier with series tools
Product release in house parts
2)
„R“
Parts to be confirmed 1) Delivery Prod.tests
100% parts „P“ •
• •
1) 2)
Maturity levels for documentation are matched with development phases Progress of components design in the component application structure Maturity level describe the „finalization of design“: A-sample 1), B-sample (‚V‘), C-sample (‚E‘), D-sample (‚P‘), finalization of development ‚_‘ The final release of development, is done as „Engineering release of entire product“ by the responsible person for development before start of production tests (QG3)
• • • •
Supplier management activities start simultaneously with the development processes Planning of product release starts with „P“ and awarded series supplier Finalization of initial inspection report requires ‘_’ All in house and purchased parts have to be assessed „green“ before SOP (ISIR).
For A-Sample documentation in EDS is not obligatory Preliminary release is done with risks in case tool lead timing exceeds end of C-sample accelerated tests and is released by project leader
Daimler Trucks | 76
Component related releases (maturity level logic) For MB: compare to process instruction V019E042
1)
X
Content
2)
(no EDS doc.) Finalization Design „A-sample“
V
E 2)
•
Integration of innovation/technologies into series development (entire product). • Alternatively, competing concepts are assessed regarding their series development feasibility
•
Functional validation of determined technical concept from the innovation phase • Fulfillment of requirements concerning functionality of components/ software and the required package space are being targeted
•
Procurement parts/ EE-content as a prototype to ensure innovations and concept investigations (Bsample)
•
Procurement parts / EE-content as prototype to ensure the reliability and durability (C-sample). Manufacturing process/ material as close to series as possible (prototype-tools)
•
Finalization Design „B-sample“
E
Consequences
E 2)
•
Testing components/ system/ EE-content of entire product with respect to reliability and durability.
Procurement of parts/ EE-content as a prototype part to ensure innovations and concept investigations (A-sample) • Realization of concept decision
Finalization Design „C-sample“ A 2)
Finalization Design „D-sample“ („C=Series“)
„_“
2)
Finalization of development and documentation
1)
Change Management
P
•
In principle finalization of design activities Start of change management only in case of occurring damages during testing or manufacturability problems in the production process. • Finalization : Drawings, part numbers, variants, bill of material incl. product properties, components coded in bill of material (SAA), review of manufacturability, materials and process parameter. • Specification if parts have to be confirmed out of series prod. tools. • Finalization up to gate 4 (or gate 6 for C=Series tools)
•
•
Finalization of development Close to gate 3 with sufficient timing to finalize product release • Proven reliability (statistical securing of released design status) • In case of necessity short term confirmation of part from series prod. Tool is possible • For purchased parts series supplier is awarded
•
•
•
For A-sample documentation in EDS is not obligatory
2)
MBTrucks/MFTBC global
DTNA
RfQ, selection & contractual commitment of series supplier. • Awarding of series tools or series manufacturing equipment • Procurement parts from series prod. tools. (D-sample parts for component validation, pretryout, homologation, if necessary C=Series tools) • Finalization of configuration codes („V“) Finalization of product release activities Procurement for production tests • Parts/EE-content can be procured for the defined application incl. spare parts • Release of configuration codes („_“)
Daimler Trucks | 77
2. P
Maturity Lev.
Requirements for releases and consequences of delays Release Consequences of missing /delayed releases • 1)
X
2)
• • • •
2. P
•
V
E 2)
• • •
E P
E 2)
A 2)
• • • •
„_“
2)
• • • • •
Connection of ISIR and ‚_‘- release
No results from A-sample testing Restricted evaluation of requirements regarding space, function, model variants, target weight ... Missing input for concept selection Req. specs./implem. specs. phase (request develop. suppl.) delayed Delayed start of in house development Cost planning delayed
•
No procurement of prototype parts Assembly/Testing of prototypes not possible Delayed prototype tests (shortened test period, statements deduced from test results with lower quality, …)
•
Its not possible to assign a) Series suppliers incl. tools b) manufacturing equipment Punctual installation of manufacturing equipment is at risk Increased risk regarding time, budget and resources Parts evaluation not completed Delay of production tests/ tryouts Product liability risks Spare parts can not be ordered Delay of sales process/ launch Assembly test has to be done manually
1) For A-Sample documentation in EDS is not obligatory 2) MBTrucks/MFTBC global DTNA
•
•
•
Only parts with drawing release ‚_‘ and product 3) release (ISIR ) can be assembled into customer vehicles. Product release process starts before „during“ or after ‚_‘ –release Important: In case the product release process is started before ‚_‘ –release, its important to assure the equality of 3) released and PPAPed ZGS (drawing version). If the initial samples are requested based on ‚P‘, then ZGS of ‚P‘ and ‚_‘ have to be identical. Otherwise a change management process is necessary. Product release should not be finalized before ‚_‘ for the following reasons: • Customer readiness would be confirmed, despite an insufficient maturity level. • In case of any ZGS changes up to ‚_‘ the product release becomes invalid. • After product release, parts can automatically be ordered by machine, in this case ‚_‘-release shouldn’t be missing
3) ISIR: initial sample inspection report, ZGS: Zeichnungsgeometriestand
Daimler Trucks | 78
Rule of thumb for tool process ( see: purchased parts, in house parts are identical) 4
Finalization development
Further securing until finalization of design
C-Sample testing
no
P A Finalization design
–
Release Develop. docum.
Development
Purchasing (purchasing of parts)
Suppl. Mgmt. (SQ)
Does the part has to be confirmed out of series prod. tools?
Docum. for series order placement and tool manufacturing
Certification run
TBT-D1
Date of delivery
Optional confirmation run D1-Components 2)
Finalization purchasing 2)
ISIR Start
PPR: Product rel. 4)
Production
3)
D1-Sample
Finalization Dispo. Production
tests
D2-Sample = Initial sample
Tool process Supplier
–
Assembly of entire product for certification
Hand-over of finalized drawings to procurement incl. unit numbers (from SM) Request for Quote Series suppl.
yes
2. P
Adequate securing (reliability 1)
3
Design
Optimization Assembly product /process Testing series tools Initial part (not customer ready)
1)
Corresponds to at least accelerated tests for vehicles or overcharging test rig for aggregates D1-sample parts for confirmation are prototypes, have to be purchased at prototype prices (not series purchasing contract) 3) Date has to be determined for each part – can be before or after ‘_’. ZGS has to be identical. 4) PPR: production process and product release. Initial sample test report is written „ISIR“ (Product „green“, process min. „yellow“) 2)
Daimler Trucks | 79
Link between release of parts, codes and sales C-Sample available
Finalization of LLtool release
6
5
100% customer ready parts, start of prod. tests
Finalization Design
4
1
Finalize accelerated tests or overcharging test rig
Provision D1-Sample parts
SOP
3
Finalization development
2
C-sample testing Finalization development
Finalization design
2. P
Normally releases are staggered depending on tool manufacturing time (months + time to request calculated up to D2-part) Milestone labeling: MB Vehicle F1(18) F2(15) Fx(13) F3(12) F4(9) F5(6) Aggregate: long/medium/short
1
2
Drawing „P“ documented
4
Finalization product release
Request Series request Manufacturing series tools
Optimize tools
Max. tool time
Assembly1) Confirm. D1 entire product and certification
Sales documentation Test vehicle configuration for production tests Includes preparation and implementation of pre-tryouts
D2-part
3 Confirm. D1-components
Configuration codes release „V“
1)
6
„_“ documented
5
5
Confirm. „_“ Finalization 1
2
Pre-run supplier Preparation location
Definition:
3 7 71
2 3 Production tests
1 All confirmation relevant parts, according to their tool lead time, have to be released until 1 (_Fx for MB Trucks), so that they are available as D1-part for 3
(especially aggregate projects: if 100% parts are relevant for confirmation this is Gate 4 Finalization Design (100% parts ‚P‘) Careful: if 100% parts are relevant for confirmation, 2 is at 1 Date of delivery D1-sample components Finalization of first ‘_’ releases (parts not relevant for confirmation) With „Final. Design („P“-parts) configuration codes, and all their interactions, are released („V Code“) and with „Final. development“ (as „_“-parts) final confirmation occurs with „_“. 6 Final. development (100% parts ‚_‘), corresponding to date of delivery of D2-sample: Start finalization product release 7 Start production tests 2 3 4 5
Daimler Trucks | 80
Phase of production tests1) 2 Production test 1 MM Production test 2 MM Production test 3
MM
Test Analysis/Optimization
Prod. Test 1: Line complete
Prod. Test 2: Quality
Prod. Test 3: Cycle time
•
station sequences/ stations in automatic mode. • Reconcile manufacturing equipment and product
•
Ensure surface and dimensional requirements • Ensure bonding techniques: welding and riveting
•
Validate work instructions • Staffing complete and start employee training
•
Fulfill pre-delivery inspection • Product- and process release of entire product
•
•
Ensure process flow
Ensure product quality
1) DTNA: Pre-Series, productions stages are considered before final assembly
Ensure process short term process capability of entire product • Ensure and optimize production peek (number of units) Ensure availability of parts and components • Validate logistics • Employees trained within production tact
Ensure process cycle time
Daimler Trucks | 81
2. P
3
Four defined ramp-up methods linked to projects according to their degree of complexity 10
9
8
Special Milestones MB-Truck
KB
Z1
Z5
For B-sample
Category 1
Ex
(Product project)
6
7
7a
Definition vehicle
A
Z1
Z5
Definition vehicle.
2. P
Category 2a
Ex
Prototype
Sample vehicle
Sample vehicle Pre-series vehicle (FX)
MP
Opt.: Definition veh. Definition vehicle
PT1
PT2
Pre-series vehicles (FE)
Category 2b (Difficult Start of production)
Ramp Up
Ramp down
Ramp down
Series (FE) Optional: Sample vehicle
MP
Pre-series vehicles (FE)
Category 3
Ramp Up
Ramp down
Series (FE)
(Easy Start of production) Opt: Pre-series vehicles (FE)
Ordered by internal customers of Daimler Trucks Note: Categories are explained for vehicles, but they can also be applied for aggregates!
Ramp Up
Sample vehicle Opt: Pre-series vehicle (FX)
Daimler Trucks internal*
Series (FE)
Series (FE)
Opt.: Pre-testing veh. Opt.: Prototype Sample vehicle
0
PA
PT3 MP
1
For D-sample
Daimler Trucks internal*
(Complex Start of production)
2
3
(FA) F1 F2 FX F3 F4 F5 (FE)
For C-sample
Pre-testing vehicle
4
5
* e.g. Show Trucks, Engineering Tryout, Customer Demonstration Unit, …
Ramp Up
Ramp down
Ordered by external customers
Pre-series vehicle (FE) = parts are 100% customer ready external customers Pre-series vehicle (FX) = parts are not100 % customer ready only for internal customers PT1, PT2, PT3 = Production tests D-Sample = Depending on quality possibly also for external customers (release required)
Daimler Trucks | 82
Truck and aggregate projects are linked through important processes and defined synchronization points. 10
9
8
7a
7
Vehicle req. specs
6
5
4
3
2
Vehicle implem. specs Comp. req. specs
Comp. implem. specs.
Assembly B-sample Test (Functions)
Assembly
Certific. run
PT1
PT2
PT3
Ass- C-sample Test embly Function + Reliability
Sys.-LH
Workshops
Contents of Synchronization 10
Aggregate
Aggr. implem. specs.
Design B
LL-tool release
req. spec
9
8
impl. spec
7a
Depending on the project scope in a vehicle or target vehicle
7
Aggr. req. specs. Comp Com. implem. req. specs spec
6
B-sample test
Series tooling, but not necessarily: •Series machines •Series location •Series process/ tact
Into a target vehicle
5
C-sample test Components available for target vehicle testing
4
Aggregates certified after PT2 •Series tooling •Series machines/ location •Series process •Series quality •not yet series tact
3
2
D-pretryout Cert. run
Only applicable for: a) Modification of aggregate in new truck (aggregate with minimum maturity level D) b) New aggregate in modified truck (truck with minimum maturity level D) c) New/new combinations require modification (see following page)
PT1 PT2 PT3
Daimler Trucks | 83
2. P
Truck
Example: Synchronization „New/New“ over various aggregates 10
9
7a
8
7
Concept
Vehicle
Vehicle spec. book Sammel-AEF
100% V ATS spec. book
100% E
100% P
1
IF K1-5 Vehicle Simulation
6
PA Brackets
IF K1-5 Vehicle Simulation
3
Assembly B
2. P
After treatment of exhaust gases Engine
7a
8
A
Concept
100% „_“
V
IF
E
IF
Assembly
3
P
“_“ Complete System
Drawing PA
DVerification
Testing C-Sample
Drawing PA
Complete System Validation 2000h
Testing B-Sample
Tooling Timeline
Prototype C
IF – Interface Freeze LS – Load Spectrum Mat. – Maturity ATS – Aftertreatment System PA – Parts Availability TO - Tryout
ATS B50 Engine B0
2
Simulation D
Drawing
Prototype B
TO1 TO2 TO3
4
Calculation B Drawing ATS-Housing
Homologation
Design D
Design C
Design B
PA Brackets
C-Sample Test (Function)
5
Simulation C Build-Up A-Sample
6
1
K1-5
Corrosion C-Sample Test (Reliability) Vehicle Rough Road Mat. C
6
System Final spec. book Component Supplier spec. book Concept eval.
System spec. book Component spec. book concept competition
10
2
LS Mat. C
Assembly C
B-Sample Test (Function)
7 IF
IF
Pre- 4 LS Mat. C
LS MB
Pre LS Mat. B
2
6
1
PA Brackets
2
9
3
4
Vehicle final spec. book
Vehicle Components Specification Book • Packaging • Interface • Bracket Concept • In- and Outlet Variants • Input forces/ Acceleration based on predecessor vehicle
10
5
6
ATS C100
ATS B100 Comp. Sys. B100 Engine C0 (Engine + ATS)
Engine C50
Product Release PPF Components Complete System
2
5
Comp. Sys. C100 (Engine + ATS)
Cert. run
1
Agreement for synchronization of K-Dates (K1, 2, 3, 4 or 5) between vehicle and ATS after concept competition.
2
In case of a new ATS design and new vehicle project, enough time needs to be considered between vehicle testing and correlating design freezes.
3
Load spectrum based on A-Sample vehicle and B-Sample ATS
4
Load spectrum derived from B-Sample vehicle and C-Sample ATS
5
Data transfer between engine thermodynamics and ATS
6
Agreement between Vehicle and ATS regarding relevant components as well as release planning to ensure ATS pre-testing
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3.Methods 1.
Page Goals and principles of CVDS 3.0
1. Overview
1. Overview
6
2.1.
Product Creation Process (P): 10 modules/ 11 sub-projects/ 32 roles
9
2.2.
Quality Gates for truck- und aggregate projects (definition, content, responsibilities)
22
2.3.
Main content/ roles and their tasks during project time
39
2.4.
Main topics and details
72
Planning Assessment Reporting Steering
87 90 95 97
2. P
2. Product creation process (P)
3.1 3.2 3.3 3.4 s
3. Methods
3. Methods
99
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CVDS methods
Planning What do we have to work on? When should this be done?
Assessment s
1
2
3
What's the status of my processes? Am I able to solve my problems?
4
PM-Software
3. Methods
Steering Solving problems with decisions
Reporting Visualization of status, problems and other open issues.
Execution of integrated product steering
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CVDS method planning: Planning Implementation steps Implementation CVDS 9
A. Creation Framework Schedule
8
B. Extension Master Plan
0
C. Optional detail planning
Project leader A-Level Sub-project leader B-Level
• The critical path and Quality Gates will be developed in collaboration with the product planning / project lead. • Critical path means to identify the activities which drive the duration of the respective process modules. • The position of the Quality Gates is to be derived out of the critical path.
• As soon as the project team has been named, • planning will be detailed for every functional department respective role (based on the Framework Schedule) I.e. through discussions of the CVDS content with the project team, the project specific Master Plan is to be created.
Concluding more detailed schedules can be created in RPlan in reference to the overall logic of the critical path and Master Plan.
• The result will be transferred into RPlan.
*) RPlan is the standard-IT-tool for planning, steering and reporting within CVDS
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3. Methods
Leader of working packages C-Level
CVDS method planning: Roles and responsibilities within the P Project leader •
Agrees the strategy, objectives and goals for the project with PEC.
•
Plans project in of time, cost, quality, targets and resources together with Project Core Team. Performs the overall, cross-functional operative management of the project to ensure that project objectives are achieved. Specifically manages and tracks timing, budget, variable cost, implementation of project scope against targets. Responsible for ensuring that requirements and Quality Gate criteria are successfully met. Reports project progress to PEC to ensure the project’s overall direction and integrity. Performs management of the risks of the project, including the development of contingency plans. Manages stakeholder expectations and removes roadblocks. Directs and motivates the project team.
•
•
3. Methods
• •
• •
Sub-project leader •
•
• •
•
• •
Prepares plans and resource requirements for the team’s work and agrees it with the subprojects and project manager. Serves as coordinator, providing task and technical leadership, and facilitates the execution of his portion of the project plan Implements gate-criteria in the respective functional area. Reports to and advises the project manager of success or deviation from plan. Identifies and advises the project manager of any roadblocks and risks associated with a work package. Initiates corrective action where necessary. Communicates with management in the functional area. Motivates the team and monitors work to ensure quality control.
Leader of working packages •
• •
• •
Provides the required expertise or specialist knowledge to the project, in of fulfillment of targets. Carries out agreed activities at the assigned times. Assesses and communicates process progress (expected targets) regarding execution, issues and risks to core team leader or project manager. Resolves technical problems related to his or her functional area. Introduce new processes, where necessary, and develop a high level implementation plan and design measures and systems to ensure that the new processes work effectively
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CVDS method planning: Role and milestone abbreviations Role abbreviation
7a
7
QE
060
Process start Process end
Example Role-ID
7a
Process-ID
7QE060b
7a
QE
All risks
060
a 7a_7QE060
FMEA initial position (components)
Quality Gate Role-ID Process-ID Milestone-ID
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3. Methods
7aQE060a
Milestone abbreviation
Advice to test planning 7QE060c List of measures
CVDS method assessment: Connection of project planning and assessment Project planning
Project assessment
Project leader A-Level
3. Methods
Sub-project Leader B-Level
Assessment in RPlan
Process1)
2)
target)
Process1)
2)
target)
Process1)
2)
target3)
•
The Master Plan consists of various roles:
•
Roles s are described within the process
•
Each process (1) has a target (3), which has to be reached. If necessary processes are subdivided by milestones. Additionally each process is described with a detailed information(2).
• • • •
•
Traffic light status Status Measures Degree of fulfillment
The assessment of a target includes traffic light status, explanation of this status, measures and the degree of fulfillment
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CVDS method assessment: Future-oriented assessment of processes in RPlan Gate n+1
• • • •
forward-oriented -1 months
ca. + 6 months
The implementation of all activities, out of project master plan, are continuously assessed with traffic lights. Regular assessments with project serve for status assessment and to derive counter measures. Assessment is carried out for all processes within the timeframe between last month and the following 6 months. Explanations and measures for traffic light status are added. Progress documentation can be added to RPLan as linked documents.
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3. Methods
backwardoriented
•
Gate n-1
Role 3 Role 4
Gate n
Role 1 Role 2
Assessment
CVDS method assessment: Visualize the target fulfillment of a process using future-oriented assessment 3) Assessment process
Traffic light definition Color
No
Measures defined
3. Methods
No
Target met/ Achievement secure?
1) See Checklist on following page 2) Target always refers to Time, Quality, Costs 3) Corresponds to CVDS monthly reports in RPLAN
HELP NEEDED • The status of the specified content does not fulfill the defined targets2) • There is no secured and confirmed action plan that enables the fulfillment of the following customer process targets
Measures secure?1)
Yes
Process
Description
Yes
PROBLEMS – BUT WE HAVE A GOOD PLAN • The status of the specified content does not fulfill the defined targets2) • There is a secured and confirmed action plan that enables the fulfillment of the following customer process targets without implication on the project
EVERYTHING OK • The status of the specified content does fulfill the defined targets2) • The defined prerequisites for the following customer process are fulfilled
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CVDS method assessment: Securing of measures is verified by the following checklist Checklist
Yes
No
Effect
Were the measures approved by the process customer?
Measure is secured
Are all resources, necessary for the measures’ execution, available?
Is it possible to implement the measures during the agreed upon timeframe? (Max. until next QG) Do Project targets remain unchanged (time, quality, costs)?
yes All questions answered with „Yes“
no Measure is not secured
Is it possible to make up for delays und can the overall project schedule remain unaffected?
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3. Methods
Do we have clear evidence of the measures problem solving capability?
CVDS method assessment: Project-status 1): Compare planned and real status Example
Procedure
• •
Assessment date
A target curve is defined A target area/tolerance range is defined for the target curve.
Planned progress
Progress
Green: Status according to plan Yellow: Minor deviation – still acceptable means: in yellow area Red: Significant deviation - unacceptable means: in red area
100%
Real progress 3. Methods
•
Start
End
Process step
1) Corresponds to assessment of MLMR
• • •
For each process target status and tolerance area have to be considered individually. For each assessment date real status is recorded The real status assessment determines the traffic light In case of a „yellow“ or „red“ assessment, measures need to be defined, to get back on planned track
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CVDS method reporting: Monthly reports Hierarchical assessment and standard reports
Project overall
Sub-project
Pre-requisites and procedure QG-Reporting Committee
•
The logic of assessment is bottom-up (hierarchical) oriented
CVDS based Standardreport
•
For this, a standard report with following contents is available:
Connected Projects
•
Overall project status report: Traffic light for entire project and its connected projects
•
Project leader report: Traffic light of entire project and sub-projects
•
Monthly report: All project activities within reporting frame -1/+6 months
•
RR-report (only in QG-report) : Report of reporting relevant criteria per QG
Working packages
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3. Methods
Bottom-up Reporting Process
CVDS method reporting: Reporting for the QG report Logistics (TL)
Last QG
Assessment of previous QGs
2
Overall assessment of each sub-project. Reflect quality and costs (=RPLAN reporting and assessment)
3. Methods
1
3
Subjective, future oriented assessment of following QG
Current Status
1
2
3
Gate n+1
Role(s) Logistics
Next QG
Gate n
Gate n-1
See guidelines „PEC-Reporting“
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CVDS method steering: Decision based on reported red status example What is steering
Reporting committee
Reaction to failed plan fulfillment No Yes
No
Subproject leader
Schedule adaption or additional processes to ensure achievement of targets. All this is worked out, planned and controlled in close cooperation with the customer1)
Can we define a measure?
Yes
Team
Changed assessment „Yellow“
→ What are my consequences from assessment? → Make decisions: - Who does what? - How should it be done? → Which measures are implemented?
Assessment „Red“ Changed assessment „Yellow“
1) Project customer, PEC/TEC, OU, decision committee
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3. Methods
Project leader
Can we define a measure?
CVDS method steering: In case of a red light we have 3 options Quality Gate Decision
Options for QG-Decision Measure realization
B
A• Approval B• Approval with conditions/measures C• No approval • After risk assessment, C1
renewed calculation and approval n+1
n
A
n-1
by the PEC C1.1: Adapted target C1.2: Adapted target
3. Methods
and measures C1.1 C1.2 C1.3 1)
C C1 assessment C3
1)
Re-assessment for next Gate • Resubmission until uncompleted or missing C2
Risk
C2
C1.3: No target adaption1)
(Target categories: Costs, Time, Content)
Reference to (ordinarily) volatile, external, not sustainable influences
content is included or solved • Project cancelation/ restructuring C3
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In case you have any questions feel free to :
Name
Region
Role
Yamazaki, Shinichiro
Japan
CVDS-Representative, TA/LCG
Kitagaki, Masashi
Japan
CVDS-Representative, TA/LCG
Graetz, Anton
DDC
CVDS-Representative, TG/ECN
Johnston, Jason
DTNA
CVDS-Representative, TN/OQ
Cusin, Fernando
Brazil
CVDS-Representative, TE/BO
Rai, Amit
DICV
CVDS-Representative, T/ICM
Engineering vehicles and aggregates
Seidel, Karl-Alexander
TP/EVA
Helbig, Angelina
TP/EVL
Gross, Matthias
TP/QMP
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Daimler AG Stuttgart, www.daimler.com www.daimler.mobi
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