Design For Export

1. Design For Export MPD575 Design for X Jonathan Weaver

2. Design for Export Cohort #3 Team Members: Jim Campbell Carolyn Prodin John Siemen Kathy Stroia

3. Design for Export • Introduction to DFE • DFE Process • Key Principles of DFE • DFE Tools • DFE Examples

4. Design for Export • Introduction to DF Export • DFE Process • Key Principles of DFE • DFE Tools • DFX Examples

5. Introduction to DF ExportWhat is Design for Export? • Designing and developing products for markets, outside your own country, where they are intended to be sold. • For a specific market, it is critical to: • Meet all the regulatory requirements (Homologation) • Understand and satisfy the customer’s needs and wants in that region • Design for the local market conditions (weather, road conditions, driving habits, etc)

6. Introduction to DF ExportHow to Design for Export? • Commit from Start • (KO) • Define Roles and Responsibilities • (FAO Procedure FAP03-203) • Resources • Internal Program • Contract • Export & Emerging Markets Engineering

7. Introduction to DF ExportWhy Design for Export? Camels in a Middle East Ranger

8. Introduction to DF ExportWhy Design for Export? Venezuela off-road driving

9. Introduction to DF ExportWhy Design for Export? Ranger Overloading in Thailand

10. Introduction to DF ExportWhy Design for Export? Explorer River Fording in Venezuela

11. Design for Export • Introduction to DFE • DFE Process • Key Principles of DFE • DFE Tools • DFX Examples

12. Design for ExportDFE Process • Export Product Development Process is not any different than standard PDP • Recommend slightly offset timing (behind) • Considers special export regulations and requirements • Supplies required certification and documentation

13. Design for ExportDFE Process

14. Planning Definitions and Targets Design and Development Launch Design for ExportDFE Process

15. Planning Business Models Competitive Analysis Market Research Product History Resources Definitions and Targets Vehicle Package / Styling Suppliers Identified Vehicle Program Plan Market Definition Market Leadership Attribute Definition Reliability Design and Development Design & Release Prototypes Testing Change Control Engineering Sign-off Quality Planning Quality Execution Launch React to Customer Monitor Field Data Confirm Capability Early Production Build Confirm Part Levels Design for ExportDFE Process

16. Design for ExportDFE ProcessVehicle Program Plan • Detailed plan that defines the key program milestones and timing and is supported by detailed work plans. • Ensures consistent, robust and timely approach to program deliverables • Identifies critical metrics for each milestone • Measures program status vs. deliverables • Can be scaled • Allows team to understand program critical path and effect of changes

17. Design for ExportDFE ProcessVehicle Program Plan • Identifies key export market dates • Export Job #1 • Modification Center Start-up • OK to ship • Identifies special builds and timing • Export CP • Build froms • Export specific part required dates • Identifies appropriate testing and timing • Homologation certification • Witness Tests

18. Design for ExportDFE ProcessMarket Definition • A process that identifies legal, local operating, and customer conditions based on prior experience and local market input. • Increased Customer Satisfaction • Expedites definition of requirements for unique programs • Uses Market Feedback

19. Design for ExportDFE ProcessMarket Definition • Identifies specific regulatory requirements • Safety • Emissions • Defines the operating conditions in the market • Temperatures / Environments • Driving conditions • Fuels • Highlights customer needs / wants • Entertainment • Appearance • Special options

20. Design for ExportDFE ProcessMarket Leadership • A structured customer feedback that translates local customer input into engineering assumptions to meet the customer and market needs. • Improves profitability and image • Voice of the customer • Direct contact with customer provides program and market specific data • Increased Customer Satisfaction

21. Design for ExportDFE ProcessMarket Leadership • Customer Drives in the Foreign Market • Competitive Drives in the Foreign Market • Dealer Visits in the Foreign Market • Journalist Interviews • Early Warning Evaluation Vehicles Directly in Region

22. Design for ExportDFE ProcessAttribute Definition • A structured method used to develop functional targets by comparing existing products and competitors for critical vehicle attributes • Compares existing products and competitors in specific market • Main Critical attributes can be expanded into market specific • Establishes baseline to compare status • Establishes basis for evaluating changes • Establishes a process for rating each attribute

23. Design for ExportDFE ProcessAttribute Definition • Need to establish attributes in relation to export market, not parent vehicle in home market

24. Design for ExportDFE ProcessReliability • Set of quality disciplines that are aligned with the product development system used to ensure the delivery of a reliable and robust product. • Customer satisfaction is #1 priority • Prevent problems instead of detecting and correcting after they occur • Standardized Processes • Includes reliability principles in program plan

25. Design for ExportDFE ProcessReliability • DFMEA • PFMEA • DVP&R • Control Plans

26. Design for ExportDFE ProcessReliability: FMEA • Need to consider export requirements • Different Safety • Different Emissions • Need to consider export conditions • Different Roads • Different Driver/Owner usage • Need to consider export environment • Temperatures • Humidity

27. Design for ExportDFE ProcessReliability: DVP&R • Need to address export test requirements • Safety (Speeds / Modes) • Special Tests (shipping / transport) • Need to address export market conditions • Temperature extremes for new market • Humidity extremes • Chemical exposure • Durability • Road conditions • Power train drive cycles

28. Design for ExportDFE ProcessChange Control • Process of understanding the impact before making a change • Ensures team members understand the impact of changes before a decision is made • Ensures design intent parts are available for testing, builds and launches • Downstream impact understood

29. Design for ExportDFE ProcessChange Control • Parent vehicle changes need to consider export market impact • All changes need to address export certification / approval process (if already approved)

30. Design for ExportDFE ProcessEngineering Sign-off • Certification that the vehicle will meet customer requirements, quality, emissions, safety and other objectives. • Team event • Provides a consistent, formalized approach • Ensures all tests/evaluations are complete • Must be met before launch phase • No further design changes

31. Design for ExportDFE ProcessEngineering Sign-off • Need to have ESO for export vehicle program • May need export market certification, or witness sign-off

32. Design for ExportDFE ProcessQuality Planning • A supplier focused process to ensure that components meet specific performance criteria and can be delivered in designated rates, flows and timing. • Adds discipline to each stage of the development process • Assures issues are properly addressed • Early identification of concerns and issues • Means for supplier to communicate product quality requirements to sub-suppliers • APQP at Ford

33. Design for ExportDFE ProcessQuality Planning • Need to verify export requirements are considered • May need to include in certification

34. Design for ExportDFE ProcessPart Submission Warrant • Final sign-off that the supplier will meet all engineering design requirements and the process has the capability to meet requirements during actual production runs. • Confirms part design meets requirements and can be delivered with quality • Ensures production tooling is in place and running at production conditions • Enables flawless launch by ensuring quality parts

35. Design for ExportDFE ProcessPart Submission Warrant • May need to include in certification • Supplier may not be able to self certify • May require further ISO9000 certifications

36. Design for Export • Introduction to DFE • DFE Process • Key Principles of DFE • DFE Tools • DFX Examples

37. Design for Export Tools • It is important to compile and have access to comprehensive information regarding requirements and processes to demonstrate compliance in other countries • Tools assist the engineer and Program Teams in making effective strategy decisions regarding regulatory compliance • A major tool for capturing this information is a database where both Regulatory and Non-Regulatory (Local Market) requirements are captured

38. Design for Export ToolsFord Motor Company Tools • Ford Motor Company utilizes a set of tools to identify both Regulatory and Local Market requirements • For Regulatory requirements, Ford has (3) major tools: GRID, WISE and the Interactive Homologation Diagram • For Local Market requirements, the major Ford tools are the “Book of Knowledge” and WISE

39. Design for Export ToolsFord Motor Company Tools • GRID • WISE • Interactive Homologation Diagram • Book of Knowledge

40. Design for Export ToolsFord Motor Company Tools GRID – Global Regulatory Information Database • GRID is a highly comprehensive database that provides engineers with the following: • Details the entire Homologation Process – the process necessary to obtain approvals to sell vehicles for most of the major homologation markets (includes testing, documentation, conformity of production and acceptance of domestic certification as equivalent.

41. Design for Export ToolsFord Motor Company Tools • GRID provides (continued): • Corporate Regulatory environmental and safety requirements and regulations.  • Ability to perform searches by country, region, keywords, effective dates, systems and vehicle types • Ability to generate standard reports on country profiles, regulations by country, emissions and fuel forecasts, fuel properties information, and homologation information

42. Design for Export ToolsFord Motor Company Tools • GRID provides (continued): • Users with continual updates, via email, of all regulatory updates and pending changes

43. Design for Export Toolswww.ford.grid.com

44. Design for Export ToolsFord Motor Company Tools • GRID • WISE • Interactive Homologation Diagram • Book of Knowledge

45. Design for Export ToolsFord Motor Company Tools WISE - (World-wide Integrated Standards for Engineering) • WISE contains both Regulatory and Non-regulatory requirements • WISE was the predecessor to GRID • Contains most of the engineering standards and procedures used by program teams – including WCR, SDS, corporate guidelines, test procedures and engineering procedures

46. Design for Export Toolswww-wise.ford.com

47. Design for Export ToolsFord Motor Company Tools • GRID • WISE • Interactive Homologation Diagram • Book of Knowledge

48. Design for Export ToolsFord Motor Company Tools Interactive Homologation Diagram • A system based method of finding regulatory information. • Allows users to click on different areas of the vehicle diagram for information • Provides links to other web sites (internal and external), pending recall information, safety design guidelines and Ford acceptance criteria

49. Design for Export Toolswww.ese.ford.com/aso/asr/reg_bb/

50. Design for Export ToolsFord Motor Company Tools • GRID • WISE • Interactive Homologation Diagram • Book of Knowledge