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V363 – All hands review Sept 13 th , 2012.

V363 – All hands review Sept 13 th , 2012. Agenda. Program Build Event timing Cosma part content Schedule A summary Facility update Tool order Status Part Feasibility Status Die tooling timing Status Assembly tooling Status Tier 2 Status PPAP Projections per build event

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V363 – All hands review Sept 13 th , 2012.

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  1. V363 – All hands review Sept 13th , 2012.

  2. Agenda Program Build Event timing Cosma part content Schedule A summary Facility update Tool order Status Part Feasibility Status Die tooling timing Status Assembly tooling Status Tier 2 Status PPAP Projections per build event Quality team update Next steps

  3. Program Build Event timing Open question on TTO build, when will this take place? 2 weeks prior to TT MRD or at start of TT MRD? Need confirmation on build event vehicle quantity

  4. Cosma part content DS73-F281B09-AG

  5. Schedule A Summary EXAMPLE ONLY

  6. Facility update - Milestones • June • Groundbreaking: 25th • July • Pad Built: 13th • August • Foundations Poured: 10th • Structural Steel: 31st • Utilities Installed: 31st • September • Roof Constructed: 14th • October • Warehouse Electrical: 26th • November • Ready for Equipment Installation: 15th • December • Office Construction in Process • January • Office Build Out: 25th • February • Final Occupancy: 15th

  7. Facility update

  8. Tool Orderstatus (Cosma Toolorder) • Tool orders pending due to: • Ford sourcing decisions • VTA approval (Ford finance) • Tooling is not quoted at latest design level • No Tier 2 pricing provided to Cosma • * CK41-V80925-BA funded to 35%, commitment was 100%

  9. Part feasibility Daily meeting schedule • Mon / Wed / Fri 1 hour meeting with PD/Cosma Plant/Toolmakers etc.on Underbody Issues • Tue / Thur 1 hour meeting with PD/Cosma Plant/Toolmakers etc. on Upperbody Issues Help needed: Feedback from the meeting is most of the feasibility changes that are approved are caught up in a ‘CAD queue’ – in some instances for some weeks? Where Cosma see issues with a part being made in EU with ‘no-issues’ support is required in clarifying process/simulation etc.??

  10. Die tooling status (Summary PTS matrix) • Stamping Feasibility: 84- Stampings • 54 green • 19 yellow (workable solution-waiting on released CAD) • 11 red • 10 no TO’s • PCF1 Feasibility: 39-Stampings • 26 green • 7 yellow • 6 red • 28 partial TO’s • 9 no C/Fixture TO’s • Stamping and Assembly Check Fixtures: • 56 sourced • 57 with LD/MP, need sourced • 55 no Locator Drawing / Measuring Points • 8 no feasibility • 94 no TO’s

  11. Assembly Tooling Status & Timing Risks • Timing Risks • LOI’s only due to lack of progressive payment agreement • MRD for Stampings from Assembly Suppliers • Working through a number of feasibility issues • Need Phase II PCF1 assembly list

  12. Tier 2 Supplier Status

  13. Tier 2 Supplier Status • Help Need with the following open items • Per meeting June 28th , Ford was to supply BOM with Tier 2 and costing details for each item by July 31st. • Based on this, the following process has been used to make progress • Obtain directive T2 listing from FNA Purchasing (8/10) • Confirm T2 List with PD (8/13-8/17) • Confirm T2 List with each supplier for agreed parts for sourcing status. (8/17-todate) • FMC terms approval to buy parts from T2 off FMC owned tooling. • NA complete, EU pending • Commercial terms to be agreed with each T2 • Transportation/handling fee needs to be agreed upon • Tier 2 pricing, transportation, handling need to be updated into pricing. • Flat release notification in Aug, 2012 needs further study and clarification from FMC.

  14. Open Concern Notices – Road Blocks NoticePN. IssueRoad Block / FMC Help Required C12536023 CK41-V200K27-A T2 Cannot meet PPAP dates due to no tooling KO C12555876BK31-V25081-B No NA Suppliers Identified C12560747CK41-V114B12-B New Assy – Cosma Quoted – awaiting sourcing direction C12562377 CK41-V/H103B73-A No NA Suppliers Identified C12591697BK31-V28442/3-A No NA Suppliers Identified BK31-V40984/5-A No NA Suppliers Identified BK31-V41058/9-A No NA Suppliers Identified BK31-V45108/9-A No NA Suppliers Identified C12588942BK31-B10746-B No NA Suppliers Identified C12574066BK31-17K755-A No NA Suppliers Identified BK31-V114A66-A No NA Suppliers Identified CK41-V101A14-B No NA Suppliers Identified CK41-5B498-A No NA Suppliers Identified BK31-B104A86-A No NA Suppliers Identified BK31-B612W70-A No NA Suppliers Identified BK31-B612W70-C No NA Suppliers Identified CK41-17K755-A No NA Suppliers Identified BK31-V114A66-AB No NA Suppliers Identified C12602935 BK31-B10912-A No NA Suppliers Identified CK41-V40C92-A No NA Suppliers Identified Current direction within PD is to ‘AC’ all open concerns with engineering estimates for cost and timing prior to Cosma submitting the related 12 Questions / Support Plan.

  15. PPAP Projections per build event

  16. Quality team update • Quality Manager and Senior QE in place. • QM: Will Drambour: Aug 1, 2013 • SQE: Ron Saylor: Aug 25, 2013 • Participating in process design reviews with engineering and integrators. • Development of Core Documentation. Pre-launch phase pFlow, pFEMA, Control Plan • Prodomax: 11/5/13-2/1/13 Massive: 11/9/13 – 2/25/13 • Paslin: 11/30/13-2/21 Cims: 11/15/13 – 1/31/13 • Amending Magna Supplier Quality Manual. • Pre-Launch Activity: 12 weeks • Burst Run 1 & Q loop • Burst run 2 & Q Loop • Phase 0 Run • 30 piece Layout, Phase 1/2 • Early Launch containment planning. Clear pass/fail Criteria to confirm upstream controls are effective in preventing quality problems from getting shipped to the customer. • Regularly communicating with Ford Kansas City key stakeholders.

  17. Wrap up • Next Steps follow up items • Thank you for your time!

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