Project 4 Xiaochang Li Masaki Watanabe Purdue University.
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Transcript of Project 4 Xiaochang Li Masaki Watanabe Purdue University.
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Project 4
Xiaochang LiMasaki Watanabe
Purdue University
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Project TeamMentor
Mr. KN Swaminathan Mr. Richard Gomez
MemberMasaki Watanabe
Purdue MBA Student 6 years working experience at Nissan
Xiaochang Li Purdue undergraduate student Major in industrial Engineering
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Project overviewProject Objective
Reduce SKUs of target partsScope
Forging partsDeliverables
Identify cost driversDevelop objective costing systemsArrive at guidelines for application
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AgendaIntroduction
Definition for SKUBenefit of reducing SKUCompetitors’ solutions
Methodology An example of crank pinAn Example of connecting-rodStatistical results and analysisStandardization guideline
RecommendationsGuidelines for reducing SKUAlternatives for reducing SKU
Learnings from India and TVS
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IntroductionWhat is SKU?
Stock Keeping Unit Defined as an unique identifier
Why reduce SKU?Easier data acquisitionSavings on engineering cost and lead timeReduction on quality problems
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What competitor is doing
39.0x41.4 (49cc)Carburetor, 3 speedKick start
47.0x41.4 (72cc)Carburetor, 3 speedKick start
39.0x41.4 (49cc)Carburetor, 3 speedSelf start
39.0x41.4 (49cc)Port Injection, 3 speedKick start
39.0x41.4 (49cc)Port Injection, 4 speedKick start
Bore up
Change toSelf Start
Change to4 speed
Change toPort Injection
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Insights from production line Unicorn
Stunner CBF
Shine Activa Aviator Dio
Stroke 4 4 4 4 4 4Cooling Air Air Air Air Air AirCam OHC OHC OHC OHC OHC OHCDisplacement
149.1 124.7 124.6 109 102 102
Bore 57.3 - - 50 50 50Stroke 57.8 - - 55 52 52
Power (HP) 13.3 11 10.3 8 7 7
Torque (kg) 1.3 1.1 1.1 0.9 0.8 0.8
Front Brake240mm
DiskDrum 130mmDisc 240mm
Drum 130mmDisc 240mm
130mm DrumDrum
130mmDisc 190mm
130mm Drum
Rear Brake130mm Drum
130mm Drum 130mm Drum 130mm Drum130mm Drum
130mm Drum
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Methodology
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An Example of Crank Pin
TVS KING 4S LPG ES
TVS KING GX-2S
PETROL ES
SCOOTY ES 60
CC-HG
SCOOTY PEP 4S 75 CC
TVS FLAME 125 ES
TVS APACHE RTR 160
ES
TVS STAR
SPORT CVTi
TVS STAR
CITY 110 ES
ENGINE NEO
ENGINE 150 ES 5
SP
Model #G419003
03DG519006
05GK619000
00DK319000
00DN419007
04DN919015
00DN819037
04DN819041
04BR118002
0R218008
0
Crank-pin #
G1020050
G2020089
K020070K302044
0N402034
0M202003
0N502016
0R102041
0R102041
0R202019
9
Diameter 30 25 6 25.1 28 28 25.1 26 26 28
Length 53 47.5 32.7 38.5 47 53 42 42 42 46
Liquid Honing Width
16.75 15 0 11.5 14.5 17.5 13.5 13.5 13.5 14.5
Weight 288 182 - 141 222 252 158 170 170 217
Price 54 31.93 42.2 34.98 44.36 47.44 36.36 38.02 38.02 42
Data Table 1
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Access Data from SAP
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How to identify key parametersBasic Criteria
Look at dimensions with tight tolerances
Record parameters whenShare interface with other partsaffecting the functionality of enginespecial treatment is applied
Always record weight
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Methodology
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ICD/MiniTab Data Entry
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MiniTab Statistical Tests
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Cost Driver Identification
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Cost Objective Function
Derived from the previous
step
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Adjustment of Trend
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Adjustment of TrendPrice= - 72.9 + 0.000017 Volume + 4.22 Diameter
Adjustment Amount = Actual Price - Theoretic Price
= 31.93 – 32.61 = -0.68
AdjustedPrice= - 73.58 + 0.000017Volume + 4.22Diameter
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Methodology
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Criteria for Standardization Purpose: find similar parts and do
standardizationTwo approaches to follow
Look at all parametersIdentify significant parameters by
engineering knowledge
How to do standardizationEliminate parts with low production volumeStandardization by looking at the cost drivers
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An Example of Connecting-Rod
Model TVS KING
4S LPG ES
TVS KING GX-2S
PETROL ES
SCOOTY ES 60 CC-
HG
SCOOTY PEP 4S 75
CC
TVS FLAME 125 ES
TVS APACHE RTR 160
ES
TVS STAR
TVS XL SUPER
ENGINE NEO
ENGINE 150 ES 5
SP NP.054
Model # G4190030
3D G5190060
5G K6190000
0D K3190000
0D N4190070
4D N9190150
0D N8190410
4B P1190000
L R1180020 R2180080
Con-rod # G1020049 G2020069 K020310 K3020419 M1020020 M7020269 N8020169 P020159 R1020279 R2020219
Big end diameter
38 32 21 30.1 36 36 33 21 33 36
Small end diameter
15 20 16 13 15 15 14 16 14 15
Length 120.1 123 76 86.8 106.4 109.3 91.1 84 101.25 98.2
Wide 18 16 11.9 14 17 17 14 11.9 14 17
Weight 201 179 60 109 155 166 125 66 131 159
Moving Price
65.28 57.35 26.29 37.38 51.03 45.68 27.77 29.28 50.29 0.01
Data Table 2
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Cost Objective Function
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Input Material Cost Input Material Cost = 0.04 Rs/g * Input
Material WeightInput Material Weight = Final Parts Weight *
RatioFinal Pats Weight = f(Specification of Parts)
Ratio = f(Specification of Part)
Final Parts Weight = - 127 + 3.57 BE + 0.847 L + 3.99 W
Ratio = 5.61 - 0.142 W
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Recap of ScrapRecap of Scrap= 0.012 Rs/g * Scrap WeightScrap Weight = f(Input Material, Parts Weight)
Scrap = - 44.0 + 0.906 *(Input Material – Parts Weight)
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Conversion CostConversion Cost= f(Parts Specification, Production Volume)
Conversion Cost = - 34.1 + 2.46 SE - 3.06 W + 0.125 L
+ 27.1 BE/SE - 0.000005 Volume
AdjustedConversion Cost = - 34.55 + 2.46 SE - 3.06 W +
0.125 L+ 27.1 BE/SE - 0.000005 Volume
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RecommendationGuidelines for designers
Make new model by modifying current parts
Consider the cost drivers when designing
Standardization on varieties with small volume
Standardization on varieties with large fixed costStandardization based on engine model
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What else we can doTo Reduce Part Cost
Increase flexibility of machines and operators
Reduce fixed cost in production
To shorten R&D Lead Time
Develop e accelerated evaluation methodCollaborative R&D with suppler and
manufacturing
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What we have learned From India
Outstanding engineering education
Abundant manpowerAmbitions to dominate
the world marketBeautiful palacesAnimal friendly cityFriendly people
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What we have learnedFrom TVS
Awareness of environmental conservationCompany Society Responsibility (CSR)Ambitions and actions to learn, change and
take risks Team spirit
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Access Data from SAP
Step 1 Search for specific part
Access the latest drawings
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Access Data from SAP
Step 3
Press to search
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Access Data from SAP
Step 4
Find parts Enter key
words here
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Access Data from SAP
Step 5Part
number
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Access Data from SAP
Step 6
Go back to the main page and go to ZCV04N
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Access Data from SAP
Step 7
2D drawings
are always
preferred