Reverse Engineering Introductory Presentation€¦ · RE Introductory Presentation V1.ppt Reverse...

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RE Introductory Presentation V1.ppt

Reverse EngineeringIntroductory Presentation



I. Objectives

II. Process, Background and Preparations

IV. Costing Results

III. Design, Material and Performance Analysis

Agenda

V. Output Recommendations and Next Steps



Reverse Engineering Mission Statement

Identify product design differences between your company and the

competition to generate ideas for entry into new markets or cost reductions

through design changes of existing and future products to increase profitability

and competitiveness.



Reverse Engineering Approach

Reverse Engineering (RE) is the systematic approach to the acquisition, analysis, costing and documentation of key competitor’s technological innovations with the aim of improving performance, reducing costs of our own products and gaining an understanding of the marketplace.

The RE process attempts to reduce design related costing errors through the involvement of a cross functional team in determining cost advantages and assumes the competitor product and/or components will be produced in our facilityusing our process know-how, suppliers, labor force and equipment.

"Note that all selected systems are assembled in di fferent vehicles that operate on the same roads under the same conditions !"



Cost Reduction Projects

�OEM expectations and requirements currently filled by competitors to help break into new markets

�Thorough understanding of competing technologies

�Transfer all design & process clever ideas to reduce current system costs & to optimize quality, performance & profitability

�Development of a standardized cost-optimized Virtual product

New Market Opportunities

ReverseEngineering

Output

RE Objectives



Overcoming mind sets

“Conviction from mature industries: innovation is n o longer needed...”

Costs may be reduced by a few cents, but it´s not worth the effort!

In a mature industry like ours, there is hardly any room to modify the product!

Product design costs have been minimized for 20 years now, there is nothing to be gained

anymore!

We have the biggest market share, that

means our product’s the best!

We tried that years ago and it didn't work then so

it won't work now!

It won't meet our current customers'

specifications!



Agenda

I. Objectives



IV. Costing Results




Process; Standard Overview

• Product segment analysis

• Market analysis

• MGPP & Technology road maps

• FMEA’s, Control Plans & process flow charts

• Customer Specifications

• Current Projects

• Historical Comp. Analysis

InputPreparation of the project

OutputPreparation Analysis of cost structure

• Establish Major Objectives

• Team set-up and training

• Selection and procurement of products

• Development of a common product structure with sub-modules before comparisons

• Staff extended teams

• Analyze differences from a technical and assembly point of view

• Prepare subsequent costing through detailed understanding of products and their assembly

• Performance & dimensional testing

• Determination of design related costs for each sub-module:

• material costs

• personnel costs

• Capital/tool costs

• Consider competitor product as if produced internally

• Analyze technical differences with focus on costs

• Derive a realistic list of action items

• Obtain commitment for Work packages

• Provide results to all involved people and departments

• Initiate project controlling using tools such as IMPACT

• List potential improvements for own product

• Evaluate related potential savings for all other products in the family

• Initiate Work packages

• Virtual Product

• Design factor for BM - Matrix

• Documentation of results

• Committed action plan with estimation of related savings

Technical analysis

Evaluation of saving potential

Planning of measures

Comparison Competitor 1

Comparison Competitor 2...

Typical Project lasts 4-8 months

Teardown Workshop



“The criterion for comparison is design related COSTS”

Material costs Labor costs Capital & Tooling costs

• Supplier related costs• Component raw material• % Component labor cost• Packaging costs• Allocations• Outside services

(plating,etc.)

• Direct labor difference• Material handling

differences• Effects on line rate• Direct and indirect labor• Based on internal

calculation rates

• Assembly equipment• Differences in

depreciation rates• Component tooling• Based on new

equipment in new plant & infrastructure

The Process



“In order to obtain a thorough understanding of cos t differences, the sub-assemblies & components must be compared rather tha n the complete product”

$0.65

$0.08

$1.15

$1.80

$0.75

$0.92

$0.34

$0.45

TOTAL = $6.14

MA

TE

RIA

LLA

BO

RC

AP

ITA

L &

TO

OLI

NG

EXAMPLE

The Process



Project Team

The Reverse Engineering (RE) Team should be made up of representatives from the following areas;

• RE Team Leader likely from Product Engineering or B usiness Development• Product Engineer with development experience on sel ected products• Process/Manufacturing Engineer with knowledge of ass embly process for

product family• Purchasing Coach for the selected product group• Finance representative• Technicians will be required during the teardown wo rkshop• Reverse Engineering consultant

Additional Team members may be called upon periodically from the following areas;

• Additional Product Engineering support (lab, metrol ogy, etc...)• Quality Engineers/Technicians• Assistance from maintenance or machine shop• External labs (material determination, etc…)



Input Preparation Analysis of cost structure

Technical analysis



Tear Down WorkshopsTear Down Workshops

Team Leader

Product Eng. A

Product Eng. B

Product Eng. C

Purchasing

Members80%

Resource Allocation 1/2

80%

80%

100%

100%

100%

20%

20%

20%

50%

50%

50%

100%40%

100%20%

100%

100% 80%

100%

6 104 8 12 1614

WEEK#



Input Preparation Analysis of cost structure

Technical analysis



Tear Down WorkshopTear Down Workshop

Manuf. Eng. & Tool Eng.

Test Lab

Bus. Devlmt.

Technician

Finance rep.

Members

100%20%

100%40%

100%

100% 100%

100% 75% 150%

100%25%

100%

40%

40%

WEEK#

6 104 8 12 1614

Resource Allocation 2/2



� Workshop Details;

� Purpose is to concentrate the competitor teardown in a short period of time with the

involvement of all team members, note that reference undergoes the exact same process

to level the playing field as much as possible.

� All team members are encouraged to brainstorm any clever idea noticed in the systems

� Performance testing and critical dimensions taken prior to any teardown (a teardown order

to be established by team for each competitor system)

� During teardown, manufacturing engineer and tooling engineer cost out

� Systems are torn down one at a time and the following performed:

• components identified and photographed

• components are measured and weight taken

• grouped together by commodity and prepared for shipment to supplier for directional quotes

• Material identification may be required by supplier or external lab

Tear Down Workshop



• Large room with several tables, chairs, peg boards and phones

• Access to Intranet and Internet connectionsfor at least 3 computers

• Access to both color and B&W printers• Access to current product costing information• Access to test lab, lab measurement equipment

and machine shop• Hand held measurement equipment and hand tools• Weight scale and Microscope• Post it notes, paper, plastic bags, markers, white board and sample containers

“Note that the room must be reserved for duration o f the project”

Reverse Engineering Team Room



Selection Criteria for the Reference Products

� The Reference Products should be;

� In the top 20% of high volume production (not a niche product)

� A basic design without all options and functionality

� For common applications also supplied by major competitors

• High volume mid-range cars and light trucks

� A version through which cost reduction opportunities can easily be transferred to most other versions

� A version between the start and peak of its product life cycle

� A product where all current costing information is available

� Consisting of standard components both made and purchased for

the division



Reference Product

� Door Lock Actuator System Reference Product:� High volume, compact design� Recent development with modern technology� All current costing information available� Relatively high volumes

Reference Product

EXAMPLE



Selection Criteria for the Competitor Products

� The Competitor Products should;� have comparable Features

� be in a comparable Product Segment (ie. Customer base, technical specification, …)

� be a World class product recently introduced

� be technically equal to or superior to Siemens

� be equal to or lower in estimated cost (preliminary)

� be a model in the peak of its product life cycle or a completely new development

� Be of alternative material to compare technical choices in some cases

“Most designs analyzed are between 3 and 5 years ol d relative to current R&D activities at competitors”

"All competitor systems provide the same function i n the vehicle!"



North American Fuel Rail Volumes by Material

02,000,0004,000,0006,000,0008,000,000

10,000,00012,000,00014,000,00016,000,000

Cast A

luminu

m

Extrud

ed A

luminu

mAlum

inum

(oth

er)

Plastic

Steel

Low C

arbo

nSta

inles

s Ste

elUnk

nown

TOTAL

M aterial

2000

Vol

umes

Market Analysis for Selection Process

EXAMPLE



Sales Forecast 2000 ($million)

317

300

226

189

71

4848

39

12724

16

34

41

85

Bosch

Delphi

Siemens

Denso (Toyota)

JECS (Nissan)

Keihen (Honda)

Nippon Injector (Mitsubishi)

Marelli (Fiat)

A isan (Toyota)

Kef ico (Bosch JV)

V isteon (Siemens Clone)

Hitachi

Kemsco (Siemens JV)

Zexel (Leaving Sector)

Sagem

EXAMPLE


Global Competitor list



Bosch

Delphi

SiemensDenso

JECS

KeihinNippon

Marelli

Aisan

Kefico

Visteon

Hitachi

Kemsco

Zexcel

Sagem

0

5

10

1 10 100

CY2000 Volume

Tec

hnic

al

Inputs Provided by 16 People from both Pisa and Newport News

JVs or Copycats


EXAMPLE



Verification Field Trips

Purpose of Field Trips:

• Physically verify the correct system as per database• General layout of system in vehicle• Fastening of system to vehicle• Ease of access to service parts• Obtain schematics from dealers



10 selected 2004 NA

Competitor Products

EXAMPLE

Final Competitor Selection



Final Competitor Selection

VS

Reference Product

EXAMPLE



Air Filter

Fresh air tubeAir Cleaner Lower

Shell

Air Cleaner UpperShell

MAFHousing

Throttle Body

Fresh air intake

Joint/Seal

Clips/screws

Joint/Seal

MAFMisc Brackets

Mis

c. s

enso

rs

Cle

an A

ir tu

be

Mount/Fastener/Isolation

Misc Tubes

Mount/Fastener/Isolation Fresh Air Resonator Clean Air Resonator

Bumpers/Pads/ID

Joint/Seal

Mount/Fastener/Isolation

Joint/Seal

EXAMPLE

Costing Envelope



Specific Design and Costing Assumptions

Actuator System Reverse Engineering

1 Costing based on 500,000 units per year for 5 year program, total 2,500,000 systems2 Variable indirect burden added to labor for assemb ly cost

3Stand alone actuators complete RE, integrated actu ators to be analyzed for clever ideas and level of integration

4Capital amortized 5 years for assembly equipment an d 5 years for component tooling, 5 years for test equipment

5Directional quotes obtained from existing suppliers for purchased components including reference products.

6 8.0% Preventative maintenance on machines included in manufacturing cost

7Greasing stations included in Processes, type of gr ease and locations taken into account, cost of grea se not included

8 90% direct labour efficiency9 42 second cycle time for 500,000 units, 240 days a nd 24 hrs per day

10 Direct labour, overhead and machine costs € 55.43 per hour11 Due to high functional overlaps, difficult to est ablish best in class for functions or components12 Manufacturing labor and capital costs estimated m ainly on component count and complexity of assembly13 Motor costs estimated wrt reference motor, no EMC protection

GENERAL COSTING ASSUMPTION

CONFIDENTIAL DOCUMENT

EXAMPLEX X X

X

$X

hack

Rectangle



Cost Analysis - Process Worksheets

EXAMPLELabor RatesDirect Labor Comp 14.16Assy Test Deka I 13.18Deka IV 14.362000 Economics / 5.5 million per year / 3 shifts pe r day/ 5 days per week

COMPETITOR

Seat/Guide Assy 300 10 0.005

Core Assy 2,000 10 0.036 1.000 82,024 $0.0149Leak Test 200 5 0.007Overmold 1,200 10 0.022 1.000 82,024 $0.0149

Valve Assy 750 10 0.014 1.000 82,024 $0.0149Lift Set 600 10 0.011 0.500 41,012 $0.0075

Sub-Total 4,750 0.090Cleanroom Misc.

Cap/Tool 100 10 0.002Sub-Total 100 0.002

Process Estimates

DELPHICapital Labor

hack

Rectangle



Fully Developed Roll-up Worksheets

REVERSE ENGINEERING TEAM Product: 10 Hole

Analysis: M. Hornby, D. Hazel, P.Bertini, C. Dwire, D. Revill, S. Ellis, J. Morris, P. Stewart, G. Mor ton Manufacturer:Others: G. Llanenza, S. Zapps Core Team: Phil Kummer, Mike Gauthier Reference Product:

Std-hrsEffic.Time-mach. Time-labor Cost (in $/unit)Name p 1000in %(min.)/unit (min.)/unit Material Dir/Ind Lab Capital Other Total

Sub AssembliesNeedle/Ball/Disc P 0.012 0.027 0.039Armature P 0.201 0.080 0.281Ass. needle-arm 0.027 0.040 0.067Lower Guide 0.000Valve Seat P 0.169 0.110 0.036 0.315Ass. lower guide - valve seat 0.000Non-magnetic Shell P 0.150 0.050 0.017 0.217Valve body Shell 0.000Ass. Non-mag shell to valve body shell 0.000Valve GroupValve Body P 0.250 0.050 0.022 0.322Upper Guide 0.000Lower Screen 0.000Seat O-Ring 0.000Orifice disc 0.002 0.045 0.045 0.092Back up washer/retainer P 0.010 0.010Stopper plate/Crush ring 0.000Assemble Valve GroupMagnetic Power GroupInlet Tube / Core piece P 0.316 0.060 0.025 0.401Coil, bobbin + Terminals P 0.052 0.052

Subassemblies/Components

at3miga5:

$2.2 million for

equipment, 10 year,

5.5 million per year

at3miga5:

Includes heat

treatment at .005 and

.164 for MIM part

quoted by supplier

at3miga5:

Official quote for blank tube

from precision components ass.

In house estimate at .255 +

.0856 for plating

at3miga5:

Slug quote from suppliers

In house estimate was .069

material and .036 for

machining labor

at3miga5:

To be included in

final assembly costs

EXAMPLE

List of Extended Team Members

hack

Rectangle

hack

Rectangle

hack

Rectangle

hack

Rectangle

hack

Rectangle



Agenda

I. Objectives



IV. Costing Results




Design

North American Door Lock System Type

Stand-Alone64%

Integrated36%

“NA market is currently mostly stand-alone whereby the EU market is moving towards Integrated”

EXAMPLE



North American Actuator Type

Linear13%

Rotational87%

EXAMPLE

Design



“Asians OEM's prefer injection molded and North Ame rican OEM's prefer blow molded”

Reservoir Manufacturing Process

Injection molded

55%

Blow molded45%

EXAMPLE

Design



“Reference actuator uses 4 components to achieve th e same function as competitors with 2”

# Total Gears

325%

425%

225%

525%

EXAMPLE

Design



Door Lock System Component Count

0

5

10

15

20

25

30

35

40R

ef. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F150

Best in Class

“Range from 15 to 34 components to achieve the same function”

Average

EXAMPLE

Design



Actuator Volume

0

200

400

600

800R

ef. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Vol

ume

(cm

3 )

Best in Class

Average

EXAMPLE

Design

“In many cases, the company’s reference product is already best in class”



Reservoir Weight

0

100

200

300

400

500

600

700

800

Ref

eren

ceT

5 Neo

n

Pac

ifica

Exp

lore

r

Acc

ord

Tib

uron

Mal

ibu

RX

8

Priu

s

Max

ima

Am

anti

Wei

ght (

gr) Average

Best in Class

EXAMPLE

Design



Housing and Cover Wall Thickness

0.0

0.5

1.0

1.5

2.0

2.5

3.0R

ef. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Thi

ckne

ss (

mm

)

Average

Best in Class

EXAMPLE

Design



Housing/Cover Resin Material

PPSP 30%GF

POM CPA66 30%GF

PBT 10-30%GF

Material

“Reference product uses most expensive material”

EXAMPLE



Agenda

I. Objectives



IV. Costing Results




AFM Benchmarking: Overall Attenuation

1012141618202224262830

Ref

eren

ce

2.7

Str

atus

3.3

Car

avan

528i

330i

E32

0

LS

Vill

ager

Sat

urn

LS

3.2T

L

Ody

ssey

Son

ata

MP

V

Ecl

ipse

Max

ima

Pat

hfin

der

Car

rera

IS30

0

Cam

ry

S80

Tur

bo

Jetta

VR

6

Pas

sat

Vehicle

dB

EXAMPLE

Performance Analysis



Motor Overall Noise Levels

54

56

58

60

62

64

66

68R

ef.

NC

V

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Mot

or N

oise

(dB

a)

Average

Best in Class

EXAMPLE




Actuator Force

0

20

40

60

80

100

120

Ref

. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

For

ce (

N)

Average

EXAMPLE




Actuator Arm Travel

0

5

10

15

20

25

Ref

. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Tra

vel (

mm

)

Average

“No standard, customer driven but need to know rang e from 7 to 23 mm”

EXAMPLE




Agenda

I. Objectives



IV. Costing Results




Worm Spindle Cost

€ 0.000

€ 0.200

€ 0.400

€ 0.600

€ 0.800

Ref

. NC

V

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Cover Cost

€ 0.00

€ 0.20

€ 0.40

€ 0.60

€ 0.80

€ 1.00

Ref

. NC

V

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Housing Cost

€ 0.000

€ 0.200

€ 0.400

€ 0.600

€ 0.800

Ref

. NC

V

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Costing Analysis: Components

Average

Best in Class

Green integrates bus bars

Best in Class

Average

Green indicates metal worm

Best in Class

Average

Seal Cost

€ 0.000

€ 0.020

€ 0.040

€ 0.060

€ 0.080

€ 0.100

Ref

. NC

V

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Green indicates simple 0-ring

Best in Class

Average

Green integrates bus bars

None

EXAMPLE



Power Group

$0.50

$0.60

$0.70

$0.80

$0.90

$1.00

Cos

t per

Uni

t

Po wer Gro up $0 .714 $0 .9 4 2 $0 .8 9 2 $0 .6 60 $0 .8 4 8 $0 .6 0 7 $0 .873 $0 .9 0 9 $0 .9 9 0

Deka IV

Deka ID

Deka NG 1

A isanB o sch EV 6

B o sch EV 14

Delp hi M M C Sag em

Valve Group

$0.20

$0.30

$0.40

$0.50

$0.60

$0.70

$0.80

$0.90

Cos

t per

Uni

t

V alve Gro up $0 .70 7 $0 .73 1 $0 .6 75 $0 .4 6 3 $0 .4 78 $0 .3 73 $0 .554 $0 .8 2 7 $0 .4 85

Deka IV

Deka ID

Deka NG 1

A isanB o sch EV 6

B o sch EV 14

Delp hi M M C Sag em

Dynamic Calibration

$0.01

$0.03

$0.05

$0.07

$0.09

$0.11

$0.13

Cos

t per

Uni

t

Dyn. Cal ' n $0.104 $0.071 $0.125 $0.044 $0.046 $0.076 $0.105 $0.058 $0.077

Deka IV Deka ID Deka NG AisanBosc h

EV6Delphi Denso MMC Sagem

Magnetic C ircuit

$0.50

$0.70

$0.90

$1.10

$1.30

$1.50C

ost p

er U

nit

Mag. Circuit $1.018 $1.268 $1.337 $0.971 $1.514 $0.947 $1.487 $1.176

Deka Deka Deka A isan Delphi Dens MMC Sage

Costing Analysis: Sub-Assemblies

EXAMPLE



Total Reservoir Cost

€ 0.00

€ 0.50

€ 1.00

€ 1.50

€ 2.00

€ 2.50

€ 3.00

€ 3.50

€ 4.00R

efer

ence

T5 N

eon

Pac

ifica

Exp

lore

r

Acc

ord

Tib

uron

Mal

ibu

RX

8

Priu

s

Max

ima

Am

anti

Green - Injection Molded

Average

“Injection molding cheaper than blowmolding?”

EXAMPLE




Clutch Function Total Cost

€ 0.00

€ 0.05

€ 0.10

€ 0.15

€ 0.20

€ 0.25

€ 0.30

€ 0.35

€ 0.40

€ 0.45

€ 0.50R

ef. N

CV

Ave

o

MP

V

Acc

ord

RX

8

TL

Civ

ic

F15

0

Best in Class

AverageEXAMPLE




Costing Analysis: Cost vs Performance

Number of Components vs Cost

Aveo RX8

Accord

TL F150MPV

CivicRef

€ 3.00

€ 5.00

€ 7.00

12 24 36Number of Components

Act

uato

r Tot

al C

ost (

€)

��

��

Trend Line

EXA

MPL

E




Actuator Noise vs Cost

AveoRX8

AccordTL

F150MPV

Civic Ref

€ 3.00

€ 5.00

€ 7.00

50.00 65.00 80.00Actuator Noise (dBA)

Act

uato

r Tot

al C

ost (

€)

��

��

Trend Line

EXAMPLE



Actuator Weight vs Cost

Aveo

RX8

Accord

TLF150

MPV

CivicRef

€ 3.00

€ 5.00

€ 7.00

100 150 200Actuator Weight (gr)

Act

uato

r Tot

al C

ost (

€)

��

��Trend Line


EXAMPLE



Costing Analysis: Overall Results

Total Material Cost per Unit

€ 0.00€ 1.00€ 2.00€ 3.00€ 4.00€ 5.00€ 6.00€ 7.00

Ref

eren

ce

Ven

ture

Land

crui

ser

Car

avan

Ody

ssey

Fre

esta

r

Total Labor Cost per Unit

€ 0.00

€ 1.00

€ 2.00

€ 3.00

€ 4.00

€ 5.00

Ref

eren

ce

Ven

ture

Land

crui

ser

Car

avan

Ody

ssey

Fre

esta

r

Total Capital Cost per Unit

€ 0.00

€ 0.20

€ 0.40

€ 0.60

€ 0.80

€ 1.00

Ref

eren

ce

Ven

ture

Lan

dcr

uise

r

Car

avan

Ody

ssey

Fre

esta

r

Total Tooling Cost per Unit

€ 0.00€ 0.10€ 0.20€ 0.30€ 0.40€ 0.50€ 0.60€ 0.70€ 0.80

Ref

eren

ce

Ven

ture

Land

crui

ser

Car

avan

Ody

ssey

Fre

esta

r

Average

Best in ClassBest in Class

Average

Best in Class

Average

Best in Class

AverageEXAMPLE



T O T AL C O S T

$ 0 .0 0$ 0 .5 0$ 1 .0 0$ 1 .5 0$ 2 .0 0$ 2 .5 0$ 3 .0 0$ 3 .5 0$ 4 .0 0$ 4 .5 0$ 5 .0 0

Dek

a IV

Dek

a ID

Dek

a N

G 1

Dek

a N

G 2

Ais

an

Bos

ch E

V6

Bos

ch E

V14

Del

phi

Den

so

MM

C

Sag

em

Cos

t per

Uni

t

Ma te r ia l L a b o r Ca p ita l

Cos

t per

Uni

t

EXAMPLE

PLANNED TARGET

Competitors

Ref

eren

ce

Costing Analysis: Overall Results



I. Objectives




IV. Costing Results

Agenda



Output: Customer Preferences

Aluminum PlasticCarbon

SteelStainless Steel

North AmericaEuropeNote:

BMW

VW

Renault

Opel

Mercedes

Volvo

DaimlerChrysler

Mercedes

Ford

General Motors

PSA

Fiat / Alfa Romeo Fiat / Alfa Romeo

Honda NA

Mitsubishi NA

Nissan NA

Suzuki NA

Toyota NA

EXAMPLE



Overmolded seals:• Several systems with overmolded grommets, tube extensions and tube seals

EXAMPLE

Output: Clever Ideas



EXAMPLE

Output: Clever Ideas

# Idea Description System1 Gears Hollowed out for light weight, lowest priced material (PP?) Civic2 Housing

Integrated bus bars and connectors for motor and limit switch PP material

Accord

Cover PP material using 1/2 height for housing and cover Accord3 Motor Knurled cheapest solution, lower power wrt to gearing, short shaft F1504 Worm spindle Plastic pressed onto motor knurled shaft Accord5 Connectors Integrated into housing, one piece molding w/ overmolding Accord6 Clutch Motor shaft mounted simple clutch F1507 Clutch Torsional Spring with spiral follower Civic8 Limiter Design incorporates free wheeling with no additional components Camry9 Limit Switch Sliding copper contacts Accord

10 Gear Spindles Off the shelf 3mm steel rods w/o plating MPV11 Gears Integrated clutch and limiter functions to output shaft, POM C material Accord12 Final Assembly Simple assembly with minimum components MPV

Clever Ideas



Total RE cost savings of Y%

3,4,5 Power group - Internal

1 Inlet tube – Competitor V

Adjusting tube – Competitor Z

7 Spring – Competitor X

9,10 Ball Armature – Competitor W

11 Valve Seat – Competitor X

8 Valve Body - Internal

2 Upper O-ring – Competitor X and Z

13 O-ring - internal

14 Filter - Competitor X

12 Orifice – Competitor Y

# Components reduced by X%

EXAMPLE

Output: Virtual Product



X Components, simple assembly, compact design

Y% lower cost than reference, Z% lower cost than best in class

Integrated housing / bus-bars / connectors

Plastic motor spindle

Motor

Integrated main gear / clutch spring / limit

switch

Sliding Contact

O-ring sealArm shaft

Gear Spindle


EXAMPLE



# Function/Component Description System Cost

1 Housing PP w/ Integrated bus bars, sliding contact for limit switch Accord € 0.608

2 CoverThin walled, change to PP instead of PBT 30%GF US/laser weld Accord € 0.105

3 Clutch Torsional spring with features in main gear Accord € 0.0294 Motor Knurled shaft Johnson, good performance, low noise F150 € 0.5715 Worm Spindle Use POM instead of PA 66 Accord € 0.0476 Main Gear POM C multi-purpose Civic € 0.1047 Limit switch Sliding contact Accord € 0.0228 Gear spindle 3mm diameter steel rod, cut to length MPV € 0.0109 Output shaft Follower type PA 66 Civic € 0.04910 Output lever POM C friction welded to shaft Civic € 0.05111 Shaft Seal Simple of the shelf o-ring Accord € 0.01812 Final Assembly MPV simple assembly adjusted for even simpler design MPV € 0.937

Total Cost € 2.551

Door Lock Actuator System Virtual Product Cost Redu ction Ideas

EXAMPLE





Total Cost per Unit

€ 0.00

€ 1.00

€ 2.00

€ 3.00

€ 4.00

€ 5.00

€ 6.00

€ 7.00R

ef. N

CV

Ave

o

MP

V

Acc

ord

RX

8 TL

Civ

ic

F15

0

Virt

ual

X% reduction in cost over the

reference product

EXAMPLE




Normalized Total System Cost

€ 1.000

€ 1.500

€ 2.000

€ 2.500

€ 3.000

€ 3.500

€ 4.000R

efer

ence

T5

Neo

n

Pac

ifica

Exp

lore

r

Acc

ord

Tibu

ron

Mal

ibu

RX

8

Priu

s

Max

ima

Am

anti

Virt

ual

X% lower cost than Reference

EXAMPLE



Output: Existing Systems Work Packages

T5 Reference Analysis

# Function Change Descrip tion Applications Current CostNormalized

T arget Savings

1 O-ring Eliminate 1 o-ring All € 0.03 € 0.00 € 0.030

2 Screen/Filter Replace mouth screen with pump filter A ll € 0.31 € 0.16 € 0.148

3 Filler neckThermo-formed corrugated hose

PE/PP talc filled All € 1.26 € 0.88 € 0.378

4 Reservoir Material change to PP 30% Talc filled All € 0.45 € 0.31 € 0.134

5Pump and Level indicator grommets

Change from EPDM to TPE/Y, assume 20% savings All € 0.18 € 0.14 € 0.036

T5 Reference Analysis 04/05 05/06T OT AL € 2.22 € 1.49 € 0.73 ######### € 152,322.40

Percentage 32% 22% 10% 210,000 210,000

BMW 3 Series

1 Reservoir Material change to PP 30% Talc filled All € 0.00 € 0.000

2Pump and Level indicator grommets Change from EPDM to TPE/Y All € 0.32 € 0.28 € 0.038

BMW 3 Series 04/05 05/06T OT AL € 0.32 € 0.28 € 0.04 € 18,924.00 € 18,924.00Volume 500,000 500,000

System #1

System #2 EXAMPLE



Output: Existing Systems Work Packages

Reverse Engineering Potential Savings SummaryBy Platform

$0

$2,000,000

$4,000,000

$6,000,000

$8,000,000

$10,000,000

$12,000,000

$14,000,000

$16,000,000

$18,000,000

00/01 01/02 02/03 03/04

Fiscal Year

Pot

entia

l Sav

ings

($C

dn)

LH

W Car

H Car

Civic

Accord

BR

RS

PL

JR

DR

AN/DNEXAMPLEP

latforms



� Work Packages assigned to customer teams

� All Workpackages will be rolled into the company cost saving program once DI & feasibility established

� Knowledge transfer to new programs

� Implementation team will assist customer teams

AN/DN 7

DR 8

JR 3

PL 9

RS 5

BR 4

Accord 1

Civic 4

H Car 4

W Car 6

LH 16

TOTAL 67

Platform Workpackages

Output: Implementation Plan

Num

ber of Workpackages

Platform

s

EXAMPLE



EXAMPLE

Title: Title Coach:

Leader

WP#:

N/A

Description: Implementation Stage: DI 1 DI 2 DI 3 DI 4 DI 5

Plan (Mn/Year):

Actual (Mn/Year):

Key Dates, Next Steps, Milestones:

Task Responsible Date Comments

Output: Workpackage Tracking Sheets



� Complete feasibility of cost reduction ideas

� Continued development of Virtual Product

� Carry forward Work Packages with management support

� If more competitor products can be obtained, proceed further with RE

� Invite all design engineers and project managers to visit RE room to review results and recommendations

� Invite Customers to RE Room so we can show the level of depth and the knowledge we have on ‘their’ competitors

� Ensure that all new development projects incorporate the Best Ideas and concepts from RE

Next Steps: Ongoing Activities



EXAMPLERE Ongoing Activities Annual Costs Assume $60/man-hour & 220 days/year

# Project # sys Timing Leader + NVH Test Purch Tool Manuf Qual P.C.Part time Man-Days $ Cdn Misc. Overall

1 Air Induction 4-6 Ongoing 103 3 3 10 3 4 6 2 134 $64,160 $12,000 $76,160

2 Intake manifolds 1-2 Ongoing 103 2 2 2 1 1 2 1 114 $54,560 $12,0 00 $66,560

3 System Modules 1-2 Ongoing 103 3 3 2 2 4 2 1 120 $57,440 $12,000 $69,440

TOTAL 367 $176,160 $36,000 $212,160

RE Future Projects One Time Costs Misc. Includes parts/fixtures and travel

# Project # sys Timing Leader + NVH Test Purch Tool Manuf Qual P.C.Part time Man-Days $ Cdn Misc. Overall

1 AI Truck/SUV 8-10 9/01-12/01 0 5 5 10 5 7 10 5 47 $22,560 $20,00 0 $42,560

2 AI 4 Cylinder 15-20 10/01-7/01 0 10 10 15 10 13 20 5 83 $39,840 $40,000 $79,840

3 IM 4 Cyliner 11 May/4/01 0 0 0 3 0 0 0 0 3 $1,440 $0 $1,440

TOTAL 133 $63,840 $60,000 $123,840

Total

Total

Next Steps: Future RE Activities

ProductSegments

Other vehiclePlatforms

Investments inHuman resources

Investments inAcquiring competitor

products

$

$



Thank you for your time, any questions?

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