Stage gate process aids product development #pmot

ISO9001designprocessIn the Automotive# industry thousands of individual components are designed, developed, prototyped, tested and tuned silmultaneously to be brought together as a finished car which has to meet exacting standards for safety, perfomance and reliability.

An incredible feat of engineering and project management which is made possible by the effective use of a rigorous stage gate process based on ISO9001 . Here the output of one stage has to meet pre-defined standards before the project is allowed to move to the next stage.

The key to continued success is the fine tuning of the process itself based on ‘lessons learned’ from previous projects.
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What is #Quality ?….

RolexQuality has a number of definitions, ‘fit for purpose’, ‘exceeding expectations’ ‘meeting specifications’. It can be a tricky thing to measure but we all know it when we perceive it.

Take a Rolex watch for example, the materials used in its construction, its finish, its mechanical integrity all tell us it is  a ‘Quality’ item – this is naturally reflected in its price.

Although lots of fakes exist it is impossible to replicate the original without investing the same levels of workmanship and materials into it’s manufacture. This gives us a clue as to the origin of the Quality of the object. It lies in the specification & manufacture of the object within a given set of tolerances.

This is reflected in the luxury end of the automotive industry where body panels are specified as beng within a tight dimensional tolerance which in previous generations of product may have been deemed impossible.

Such tolerances lead to a vehicle which is perceived as high Quality without the buyer neccesarily understanding why.

So, if we can capture the expectations of the customer & translate them into product specifications with tolerances we can design & build something which has increased added value & perceived customer Quality.

 

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#Lean empowerment……

TPS

At the heart of the Toyota Production System (sometimes referrred to as #Lean Production System) is the principle of ‘Jidoka’.

 According to Toyota “Jidoka means that a machine safely stops when the normal processing is completed. It also means that, should a quality / equipment problem arise, the machine detects the problem on its own and stops, preventing defective products from being produced. As a result, only products satisfying quality standards will be passed on to the following processes on the production line.”

But there is more to #Lean than this. The key component is the empowerment of the Operator to stop the process immediately a defect or potentialy defective process is discovered without referring the issue upward. The Operator can stop the production process without fear of retribution and is empowered to do so. This is a great responsibility and one which is not granted lightly, the Operator must be fully trained and the Organisation steeped in the culture of #Lean & #Kaizen (continuous improvement)

Granting  this autonomy is absolutely key to the success of the TPS philosophy & unleashes immense forces of creativity & quality improvement. 

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10 tips to minimize cost at the Design stage….

Bizplan03All companies need to be mindful of costs & for those producing products this is best done at the Design stage. Here are some suggestions:-

 

  • Before beginning the design a Product Specification is essential, this needs to have been agreed at Senior Management level.
  • The product design needs to meet the spec and no more.
  • The material choice is critical, why make it out of gold if steel will do.
  • Use minimum thickness, as long as the design meets the spec.
  • Reduce the number of components as much as possible.
  • Re-use existing design components wherever possible – this gives Purchasing negotiating strength over suppliers and reduces inventory.
  • Consider Manufacturing by minimizing the number of process steps in manufacture.
  • Hold regular Design reviews & involve other parts of the Organization.
  • Build a prototype to test the design.
  • If possible test the Design using Computer Aided Modelling.

If you need help minimizing cost at the Design stage feel free to get in touch.
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Bentley – made in Crewe, England

The News from Volkswagen Group this week that Bentley’s new luxury SUV will be built in Crewe, England is welcome news indeed, not only for Bentley Motors Ltd but also for the North West of England and the area’s supply chain.

Volkswagen Group (owner of Bentley) is investing over 800m GBP in the new SUV and creating around 1000 jobs in Bentley & the local supplbentley-suvy chain.

This illustrates the Group’s faith in the Engineering & build quality of Bentley as it was rumored that it could be built in Brataslava alongside the Audi Q7 & Porsche Cayenne.

It is likely the car will enjoy a facelift as the EXP9F prototype received mixed reviews at the Geneva Motor Show.
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#Automotive Competitive Sport………

Today Jaguar Land Rover revealed the all new Range Rover Sport in Manhattan New York. This fabulous vehicle is a terrific example of British Engineering at it’s best. The West Midlands manufacturer goes from strength to strength with double digit sales growth across the globe.

Rumour has it that JLR could sell their entire manufacturing capacity for the new Sport to China alone.

The new Range Rover sport is built to ultimate quality standards and features many examples of innovative design, from the all aluminium body shell (which is half a ton lighter than the previous model saving 15% in fuel) to the class leading infotainment system.

JLR are leading the world in automotive product design and manufacture. Long may it continue.

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Buy British because it’s British ? #business

There has been some debate in the Media recently about buying British products as a way of reducing the impact of the recession & preserving British jobs; so is this a good idea ?

We live in a Capitalist society (whether we like that or not) based on competition. The consumer has a free choice of which products to buy or not to buy & we tend to seek good value for money, regardless of origin. As a consequence we are pretty good at identifying products which deliver most “bang for the buck”.

In the 1970’s most of our Electronic products originated in Japan. Some people complained this wasn’t fair to British manufacturers but consumers continued to buy Japanese products because they were better quality and hence better value for money.

Now most of our electronic products are manufactured in China or Korea & people buy them because they are cheaper & better quality than their Japanese counterparts.

Jaguar Land Rover has been in the News recently because sales are up over 30% compared to last year, is this because these products are manufactured in Britain or because they are of exceptional quality and, though expensive, represent good value for money.

Over time products evolve and the companies which make them either grow – & their shareholders get richer or, if their products deteriorate the company shrinks, the shareholders lose money & eventually the company is bust.

So, in the long run, is the best way to preserve British jobs to buy inferior goods just because they are British or to buy the best value products whatever their origin & ensure quality increases & the fittest survive ?

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Our New Year hopes for 2013

2012 has been a pretty miserable year with freakish weather on both sides of the Atlantic, in the U.K  the highest rainfall since records began saw people washed out of house and home and businesses ruined. In the USA Hurricane Sandy battered the East Coast and several lives were lost, homes ruined & businesses destroyed.

Scandal followed scandal in the world of banking, PPI miss-selling, Libor fixing, Rogue traders etc etc

As austerity measures bite, wages decline & the economy bumps along the bottom like a flat baloon.

OK, so that was 2012, what do we want from 2013:-

  • Less emphasis on GDP and more on sustainability. The current system based on mass consumption, Consumerism & unsustainable growth fed by mountains of debt is bust ! We need to replace it with a more responsible, ecologically sound system based on managing the worlds scarce resources more effectively and equitably.
  • We need to take environmental change seriously. Whether there is a direct link between recent extreme weather & man made global warming is up for debate but there is irrefutable Scientific evidence that carbon dioxide emissions are having a direct impact on average global temperature. The long term consequences could be cataclysmic.
  • More People Power – the disaffection with the banks has led to huge defection to “community” banks like the Co-operative bank. Long may this continue. We are the mass consumers and we can have a massive impact by promoting ethical business practice & behavior.
  • Reduce our thirst for Oil – despite most of the Western world being in  recession (or near) the price of Oil remains stubbornly around $100 a barrel. There are a number of factors at work here but there is little doubt we have reached “peak oil” where future supplies will gradually decline and the price rise. We need to break the cycle by urgently seeking alternative energy sources AND reducing consumption. The Automotive industry has made great strides in recent years but nowhere near enough. Much more Innovation is needed in this area.
  • A flatter playing field – whilst workers real wages & salaries have reduced year after year the income of Senior Management & Board members has continued to rise. The gap between rich & poor gets larger every year. This defies rational thought. It is up to us to change things by greater political action, workers representatives on company boards, greater shareholder influence on remuneration committees etc etc. There is NOTHING inevitable about allowing this obscene poverty gap to continue increasing.

So there are some of our wishes for 2013. Whether they come true is up to me and you. All the best.
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#Innovation adds value and creates jobs……

Fantastic news today regarding the development of a National Automotive Innovation Campus at the University of Warwick.

Funded jointly by the Government’s U.K Research Investment fund, Tata Motors & Jaguar Land Rover, the centre will cost 92 million pounds.

David Willetts, Minister for Universities and Science, said: “The UK has world-class companies and great universities. This new investment will get them working together to deliver innovation and growth.”

“The automotive industry in the UK has seen a recent resurgence, but for the UK to remain internationally competitive we must create urgently a critical mass in research excellence,” said WMG chairman and founder Professor Lord Bhattacharyya. “Our vision is to create the National Automotive Innovation Campus where we link people, research and world-leading infrastructure to create and develop novel technologies.

“NAIC will be an ‘engine’ for economic growth, with wide economic benefit, and sustained growth from the creation of world-leading technologies. It will enable academic and industry teams to work together in state of the art buildings, with tailored equipment and digital solutions to create and integrate breakthrough technologies with a whole system approach crossing multiple disciplines.”

This is exactly the type of investment British Science & Engineering has been crying out for & is a terrific example of how collaboration between successful organizations and Government can work together to increase innovation & deliver high value added products along with well paid jobs.

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Invasion of the Robot cars….#auto #innovation

Last week saw a little reported milestone in Automotive history when Californian Governor Jerry Brown signed through legislation to allow fully automated vehicles  on California’s roads.

This took place at Google’s ‘Mountainview’ headquarters where the team have been working on a car which utilizes Google’s ‘Street View’ mapping technology, a number of sensors & some clever software to enable the car to navigate without human intervention. The company has already done over 300,000 miles testing with zero collisions so far.

So why is all of this so important ??   As Highways get increasingly congested it has long been a dream to enable convoys of vehicles to travel nose to tail in close proximity in separate lanes, breaking off as necessary, to reach local destinations.

Robot cars may smack of Sci-Fi but this development could herald a massive social change and a glimpse of the future.

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