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Automotive Projects

Automotive Industry

PROJECT DESCRIPTION

Based on the request of a customer the company, producing heat exchanger for the automotive industry, had to establish a production facility in China to deliver heat exchanger to the customer in the local Chinese market.
That in China no facility was available the whole project was managed from the only European facility in France.

PROJECT PLANNING and EXECUTION

Developing the manufacturing process together with the French team of Product and Manufacturing Engineers was the first step. A project plan according to the APQP process was developed and executed. Finally a PPAP in France was executed before the equipment was transferred to China.
In China only the construction of the facility was finished on arrival. Installations of power, compress air, nitrogen tank and piping had to be started and finalized until the arrival of the equipment. On arrival of the equipment the installations were finalized and the equipment was placed in a one-piece-flow production line, installed and trial runs began immediately. The first samples were delivered in time and according to customer requirements. In the following month PPAP was performed and soon after this the approval for serial production received.
Based on the good performance the company received a order from the customer to produce the heat exchanger also in Europe.
The Chinese operation started serial production and 9 month later achieved a pass rate of 98% as the European operation only reached 92%.

Target

Target:

Develop the manufacturing process, buy and validate the necessary equipment and tools, ship them to China and start-up the first production line in China. Deliver first sample parts from the Chinese factory 4 weeks after arrival of the equipment.

Toolbox

Tool Box:

Project Management, Team Work, Lean Manufacturing, Leadership

Achievement

Achievements:

PPAP 4 weeks after arrival in China (fastest start-up in corporation history)
98% Pass Rate (6% better than France)
5 new Project 3 month after arrival in China


PROJECT DESCRIPTION

Support a German-American automotive supplier during construction and installation of the first facility in China. Coach the foreign expats on intercultural competencies and let them understand the advantages and disadvantages of working in international teams especially in Asia.

PROJECT PLANNING and EXECUTION

Monitoring and advising the management of the company on issues during the construction and installation. Perform training sessions and day to day coaching of the management and employees on daily tasks. Reporting to the local headquarter in Shanghai.

Target

Target:

Improve Safety of the construction side and improve the intercultural competency of both, Chinese and Foreign employees, by training and coaching on their day to day tasks.

Toolbox

Tool Box:

5S and Safety, Project Management, Leadership, Problem Solving Techniques

Achievement

Achievements:

Grand Opening of the company as planned
Follow-Up Order for Production Management Training and Coaching


PROJECT DESCRIPTION

Develop the Production Manager in Operation Management

PROJECT PLANNING and EXECUTION

Operation Management Training and Coaching during 6 month with 1 to 2 sessions per week.

Target

Target:

Improve the production management efficiency

Toolbox

Tool Box:

Project Management, APQP, MRP/ERP, Demand Planning, Production Planning and Supervision, Communication, Team Work

Achievement

Achievements:

Improved Production Management
Request to develop the local Operation Management System


PROJECT DESCRIPTION

Our German partner got the order for a Task Force Project for a Geman automotive supplier to improve the performance of a Chinese supplier for aluminum injection molding parts to optimize the current process and improve the pass rate

PROJECT PLANNING and EXECUTION

Observe machining process, analyze process data and process, develop improvements and coach during implementation were the steps during the project (12 days).

Target

Target:

Increase supplier pass rate and reduce customer complaints to the supplier

Toolbox

Tool Box:

Project Management
Line Balancing
Movement Analyze
Machine Log-book
SPC Charts
AutoCad (Fixture Design)
Fishbone Diagram
Impact Analyze (Management influence
Forced Field Analysis
Achievement

Achievements:

Optimized CNC Programs and fixtures, Introduction of WI, SPC Charts and Machine Log-book, Proposal for a Development Plan
Follow-Up Order for new project


PROJECT DESCRIPTION

Our German partner got the order for a Task Force Project for a German automotive supplier to Evaluate Status of Sample Production (machining), Review PPk Reports, Analyze PPk report results and Improve PPk results

PROJECT PLANNING and EXECUTION

Observe production runs and measurement process, analyze PPk reports and develop corrective action plan (9 days). The result was that 32% of incapable results are machining related.

Target

Target:

Capability (Ppk) acceptance of customer.

Toolbox

Tool Box:

SPC Charts, Normal Distribution, Impact Analyze, Standard Ppk Analyze and calculation

Achievement

Achievements:

Optimized machining parameter
100% sample parts capable according to customer requirements


PROJECT DESCRIPTION

Our German partner got the order for Supplier Development Project for a German automotive supplier to improve the result of VDA 6.3 Process Audit result and Project Management at 2 of their supplier.

PROJECT PLANNING and EXECUTION

At the beginning the project started with reviewing Audit Findings and advice on corrective actions and following up on action implementation. Further the staff and management was coached on APQP and VDA 6.3 regulations as well in Shop Floor Management and Project Management

Target

Target:

VDA 6.3 Process Result of both supplier at least 85% after 1 year

Toolbox

Tool Box:

Process Flow
PFMEA
Control Plan
WI
SPC
Shop Floor Management
Maintenance Management
Supplier Management
Change Management
Capacity Management

Achievement

Achievements:

Supplier one achieved 80% after 45 service days
Supplier two achieved 75% after 48 service days

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