Component-related assessment of development partner Consolidated Development Control, Control , K-ESB DUNS-Nr.: 652100793
Visit
purpose:
analys is for localization Hicom Teck See Manufacturing Malaysia Sdn Potential analysi Lot 76 & 75A, Jalan Sementa 27/91, Section 27, 40000 Shah Alam, Selangor, VW 250 G (RL IN) Malaysia Rating scale first development (Tier 1): 1) : A = 90 - 100%
Audit Result
Development capability fulfilled
B = 75 - 89%
Development capability partially fulfilled
C=
Development capability not fulfilled
<
75%
Rating scale second development (Tier 2): incapable/capable incapable/capable
Component/Product
Group
Part
(with product technology)
Assessment
number
First
Development
Second
Development
(Forward Sourcing)
(Global Sourcing)
C
Capable
ASSY Door Trim Armrest : >PES< Plastic Injection
6RU
867
-
-
011
moulding >PP<
74%
Findings / Requirements / Highlights / M anagement informations Information to suppliers : -Hicom-Teck -Hicom-Teck See belongs belongs to 51% DRB-HICO DRB-HICOM M and 49% Teck See Plastic. Plastic. -Built -Built in 1962 with a capital capital of ¡Ö RM260 Mil. In 2009 and 810 employe employees es -Product -Product Portfolio Portfolio : Plastic parts (Instrum (Instrument ent panel, bumper, bumper, door trim) trim) -Customer : Proton, Perodua (ca. 95% Tier 1) and Brose (Tier 2) -Certificat -Certification ion : ISO 9001 9001 , ISO / TS 16949, 16949, ISO 14001
97 % Tier1 vs. 3 % Tier2
Management info for assessment results : The company HTS is currently classified as a typical manufacturing / Built-to-print supplier for plastic circumferences like instrument panel without slush-OB, door trim and bumper. This company is in consideration as a potential supplier for a localization project of VW Polo G-Circumferences The company is able to produce based on customer data tools and set up appropriate production processes and carry out optimization loops Significant own development development skills are lacking. lacking. CAD and CAE expertise, testing facilities and material testing. The project management is structured and based on customer specifications specifications Other differences: see report remise Procurem Procurement ent : Premise -Support through a TE-Wolfsburg engineering services Termination n of the report illustrat illustrated ed weaknesses weaknesses -Terminatio department TE-Wolfsburg TE-Wolfsburg -Introducing company/technical concept in operating department The company was requested to eliminate the weaknesses as mentioned in the report, with a nomination by an action plan. Plant : Overview of test equipments equipments, material safety data sheets, Chrome planning
Location information to suppliers Corporate structure: structure: Locations/ ocations/Development locations
Produc Products
No of Employees
Plastic parts
648
FE
JV-Partner
Main plant Shah Alam, Selangor (MY)
23 Tanjung Malim plant(MY) Plastic parts for GM and Mazda 210
Rayong plant(Thailand)
Date:
24.09.2010 Walenka Walenkamp, mp, Gijs Gijs (K-ESB (K-ESB - TE-Aud TE-Audito itor) r) Name, Organisation, Auditor Signature
Distributor :
Form
Lauck, Joachim (K-ESB)
Poerksen, Maik (VWG Malaysia)
Utzeri, Giancarlo (K-ES/B1)
Che, Fong Mei (VWG Malaysia)
Nazare, Anja (K-ESB)
Werner, Thorsten (EKKF)
Pritzke, Jens (K-ES/B1)
Raguse, Michael (EKP/Z)
responsibilitiy: Volkswagen AG, K-ES TE-Lieferantenbewertung, Brieffach 1446, 38436 Wolfsburg, Deutsc hland status 01.11.2008 (A4-Format)
Change
Technical Tie-up with Marui (since 2010)
Terence SOO Thean Hin (COO) Name, Company Signature Niedenfuehr, Sven (EKKF/2)
Seite 1/5
Component-related assessment of development partner Development Partner's Info Development location(s):
Selangor (Malaysia) Sarly Adle Bin Sarku m (Head of Division Bus.Dev.)
Contact person and position: Current Development Projects and Customers: Component or Customer Product group Proton, Perodua, Mazda, Honda…
Technolog y
Plastic parts in interior and
If the development partners already judged : If yes, from which supplier :
ASSY Door
Part name:
Judgement
-
Various
exterior
Yes
N o
Product: Middle group : Date: Rating result:
Trim
6RU
867
011
VW 250 G (RL IN)
(Emphasis [Sum 100%])
Performance
level [%]
(2%)
2. Design and simulation system
(17%)
3. Design capacity and skills
(19%)
4. Technology und Product
-
Part-Number .:
criteria for Project:
1. Specification and environment norm
Experience cooperation in SE-Process
Remarks
(4%)
5. Testing
(19%)
6. Prototyping
(15%)
7. Project competency/communication
(12%)
8. Methods of project development
(12%)
30
40
50
60
70
80
90
100
Total Result New Product
Design (Forward Sourcing)
30
50
70
90
Result analysis:
Forward Sourcing
max. 260 Points r eachable
(new Product Design )
Global Sourcing
max. 230 Points r eachable
(without new product design )
are not included in
Participants:
Evaluation criteria 2.3,
4. and 8.a the assessment
Result
=
Result
=
194 260*100 180
=
74%
Points
corresponds
to Rating:
corresponds
to Rating:
Hicom Teck See Manufacturing Malaysia Sdn. Bhd.
Volkswagen AG
Terence SOO Thean Hin (COO) Sarly Adle Bin Sarku m (Head of Division Bus.Dev.)
Walenkamp, Gijs (K-ESB - TE-Auditor) Poerksen, Maik (VWG Malaysia)
Yohan bin Mokhtar (Senior Manager Veh.Man.Proj.)
Che, Fong Mei (VWG Malaysia)
Lim Sheng Shun (Senior Manager Prod. Planning)
Saw, David (VWG Malaysia) Kainz, Thomas (QS-Auditor, Audi Ungarn)
Azmi Wahap (Manager Autom.Comp.&Eng. Division)
C capable
Yau Kian Min (Manager Bus.Dev. Division) Adam Mat Ro bi (Manager Project Development) … a lso with the
participants from DRB-Hicom Headquarters Seite 2/5
Component-related assessment of development partner Assessment criteria for
1.
Hicom Teck See Manufacturing
6R0
807
221.D
Cover front and back
6RU 867 011 A ASSY Door Trim SSY Radiator Grille 6RG 853 651
Requirement fully fulfilled
Points
Requirement generally fulfilled, slight deviation
Points
Requirement generally fulfilled, deviation present
Points
Requirement insufficiently fulfilled
Points
Requirement not fulfilled
Points
Has the development partner all the required specifications and environment standard
0
5
0
10
0
20
VW99000: available, content unknown B2B access incl. ESL available, person responsible: Project manager B2B contents should be centrally file and all involved project to be provided
2.
Design- and Simulation System
2.1
Has the development partner CAD Systems - if yes, state: Catia V5 R18 an 19: 3 Licenses
2.2
Has the development partner CAD System compatibility acc. To VW AG (VW01059) and actual System guidelines Yes, should: Catia V5 R19
2.3
Is the development partner using innovative Construction and Simulations method:
0
4
6
8
10
Plastic full simulation and warping: moldflow-analysis would be performed via tools manufacturer; Documentation available FE Simulation to vehicle occupant protection (ECE, FMVSS, EuroNCAP), head impact, modal analysis and acoustic (NVH), misusage: all about OEM/Customers CAE: Know-how limited availability, proposed amendment to optimise t ooling come from tools supplier
2.4
Has the development partner DFÜ (Data Transmission) and Data Check Module for drawing exchange
0
5
.
DFÜ: Design data management system not available VW-compliant data check module: End check & Validity: Catia V5 R19 not available
o
Datas are exchanged using CD-ROM with OEM-customer (Proton) 1. and 2. Result 3.
Design capacity and competency
3.1
Does the development partner possess sufficient design capacity:
.
(max. 50 Points)
0
16
24
32
40
0
4
8
12
16
0
4
6
8
10
Overall-design: 3Employees (CAD) / CAE: 0 Employee / Project management: 6 Employees as Programme manager plus 14 Product engineers
3.2
If 3.1 =< 24, has the development partner access/grasp to alternatives (foreign capacity): Tools supplier (e.g Moltec, DongWang, Hanguk from Malaysia, Korea, Taiwan) IDIADA (Spain): Head impact FEM-Analysis
3.3
Does the development partner possess design competency: Based on Class A-Surface-Data, component construction at OEM proton on site are performed by 3 of Hicom Teck See employees. At visited headquarters: CAD Data and drawing management / dissemination at tools supplier Employee qualification : current state matrix, without forecast CAD-Data storage needs to be improved (Stucture, partial disk, CD-Rom)
3. Result 4.
(max. 50 Points)
Technology and Product - Does development partner possess innovation potential
. 0
4
6
8
10
If yes, for which product, process or material: Used weld technology I-Panel:US-welding (2x), HSK: Hot-Plate welding, no laser trimming or Waterjet available, manual trimming support plate door trim Plastic: resin --> local resin supplier (see data sheet) Processes: Plactics IM, Blow Molding, no Slush or material after spraying, manual painting at location, using Robot in Thailand branch, Chrome: currently external supplier, internal facility will be establish in 2011 (micropores)
4. Result
(max. 10 Points)
.
Seite 3/5
Component-related assessment of development partner Assessment criteria for
Hicom Teck See Manufacturing
6RU
867
011
Requirement fully fulfilled
Points
Requirement generally fulfilled, slight deviation
Points
Requirement generally fulfilled, deviation present
Points
Requirement insufficiently fulfilled
Points
Requirement not fulfilled
Points
ASSY Door Trim
5.
Testing
5.1
Has the development partner appropriate test capabilities for functional testing:
a)
EP 84110.01: Push in / push out forces / Tear off test of fasteners (RT) --> external institute or OEM EP 84610.10: Function Test: load on arm rest / door tray --> external institute or OEM
0
8
12 16
20
1
b)
EP 84610.12 /EP85550.22: Buckling resistance of trim panel and door tray (RT,+70°C)
0
8
12 16
20
1
c)
EP 85550.30: Ball drop test on loudspeaker gril l (M=0,5 kg RT-10°C, PV3905) --> external institute or OEM
0
8
12 16
20
1
d)
EP 85550.70: Misuse by forces up 500 N on mesh, door tray b ox under RT-30+70°C --> external institute or OEM Present : Gauges.
0
8
12 16
20
1
5.2
Has the development partner appropriate test capabilities for continuous testing
a)
EP 84610.21: continuous load of arm rest and door handles (steel ball, 150 N, N=10000, -30+70°C) --> external institute or OEM
0
8
12 16
20
1
b)
EP 84610.50: Temperature agi ng +LF--> climate chamber (-30+100°C+LF, 48h) -> 1x Climate chamber (-30 +177°C+LF) EP 84610.51: climatic cycle---> climate chamber (PV2005) -> 1x Climate chamber (-30 +177°C+LF)
0
8
12 16
20
1
c)
EP 85550.10: Door closing Function test by pulling on tray (150N, -30+70°C, N=1000) --> external institute or OEM
0
8
12 16
20
1
High temp. lightfastness (PV1303, 5 cycles, 100 °CXenontest=solisi) --> external institute or OEM
0
8
12 16
20
1
Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)
-
-
-
Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)
:
5.3
Has the development partner appropriate laboratory equipment and instrumentation:
a)
Present : Dimension, Weight, Measuring table, auto. 3D measuring machine (unexact, +/- 0.1 mm). External : Flammability (TL1010) Material e.g PP : Emission behaviour, Fogging (VW 50180), density, yield stress, elongation, ball indenation hardness, melting temp.…
0
8
12 16
20
1
b)
Continuous monitoring relevant : Present --> Glossmeter Checking gauge in plastic plant : Present --> Single part and Assy
0
8
12 16
20
1
c)
0
8
12 16
20
0
d)
0
8
12 16
20
0
-
-
-
-
Block 5.3 = (Sum of a+b+c+d) / ( No. a+b+c+d)
Ergebnis = (Summe aus den Blöcken 5.1+5.2+5.3) / (Anzahl der Blöcke)
5.4
-
Has the development partner sufficient testing capacity :
0
-
-
-
20
Significant amounts are performed externally
5.5
If 5.4 = 0, has the development partner access to alternative (foreign capacity) :
0
4
8
12
16
0
4
6
8
10
external Institute : e.g. TÜV Singapore, IDIADA, local OEM Proton
5.6
The development partner has sufficient testing competency:
Present : Detailed testing plan, testing specification and documentation Present : Calibrated and documented measuring devices / no temperature controlled measuring room Gauges are used for measuring test part 5. Results
6.
Prototyping
6.1
Has the development partner an adequately equipped and organizationally independent prototyping:
-
(max. 50 Points)
0
8
12 16
20
Organizationally not independent. Plastic parts are manufactured on original equipment, assembly and construction prototypes in production
1 room for master sample storage Documentation as per PPAP-Document (Measuring report, test report) 6.2
Has the development partner sufficient prototyping capacity:
0
20
Manufacturing and supplier for single part
6.3
If 6.2 = 0, has the development partner access to alternative (foreign capacity) :
0
4
8
12
16
Suppliers of component parts
6. Results
(max. 40 Points)
-
Seite 4/5
Component-related assessment of development partner Assessment criteria for
Hicom Teck See Manufacturing
6R0 807 221.D 6RU 867 011 6RG 853 651
Requirement fully fulfilled
Points
Requirement generally fulfilled, slight deviation
Points
Requirement generally fulfilled, deviation present
Points
Requirement insufficiently fulfilled
Points
Requirement not fulfilled
Points
7.
Project competency / Communication
7.1
Can the development partners set project structures with a responsible project leader:
Cover front and back
ASSY Door Trim
ASSY Radiator Grille
0
10
Project teams through cross-functional teams in writing and communicated to client
7.2
Can the development partners set schedules with milestones and resource allocation and ensure the
execution of changes
0
4
6
8
10
Processes and to PM clearly defined / structured customized centralized project storage at the server / schedules using MS Project Milestones customer, without critical path with filling) / Open-point list available For under development project, project rooms are set up (currently as Proton, Honda) No holistic resource planning across projects / Change Management: Process standard exists, change pass transparent and complete. 7.3
Is direct communication (without translation) possible:
0
4
6
8
10
English
7.4
Is it possible to carry out a development at customer's premises
N
J
Currently no Resident Engineer near Wolfsburg
7. Result 8.
(max. 30 Points)
.
Methods of product development Is the development partner applying the QM methods
a) QFD Methods:
QFD not shown in action,part of the circumference in the form of benchmarking by means of various examples 0
4
6
8
10
b) Design-FMEA:
currently no D-FMEA (---> Built-to-print Supplier) i P-FMEA content in order including derivation process monitoring
0
4
6
8
10
c) DOE Methods:
currently not implemented
0
4
6
8
10
8. Result 9.
Assessment
(max. 30 Points) Result
(max. 260 Points)
.
Remarks The company is requested to resolve the following weaknesses: - Study the contents of B2B-Portal (Supplier manual, norm portal, VW99000…) - Ensure access to KVS - Advance their know how in terms of component design and tool-based design (plastic parts, steering wheel frame) - Advance their know how in terms of FEM-methods - Improve CAD-data storage - Implement capacity planning - Expansion of test facilities according to part testing specification (Special climate chamber, -40 ° C / upgrading auto. measuring machine including Scanpack / material analysis) - Improvements in production samples (space, processes, storage, workstations, packaging ...) - Advance know how product development methods (D-FMEA, QFD, DOE) The company was advised that a pro-active communication is required with the operating department The project organization (organization, contact person, position and contact information) is to be presented (including any changes) at initial project. At regular time intervals (agreed with the department) significant schedules, to-do lists and meeting of minutes should be provided. . In addition the supplier was informed that the next TE capability audits and project-specific performance rating be pronounced by the department.
An improvement plan must be presented upon nomination within 14 days after receiving of this report.
Seite 5/5
