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Mechanics Collaborative R&D (CoRD)

Ron Chao and Mark Strawn

V1012-May-2010

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Why• There is a need to develop ways to work with suppliers in a collaborative work mode that will take

advantages of both Nokia’s and Suppliers’ strength.• Establish Clear Ownership, while inviting more collaboration• Flexibility - VI suppliers do not have competence to design or manufacture some of our complex parts

(Sushi design/B-cover)• Improve Communication with 1st and 2nd source suppliers• Take advantage of time zones• Enables Nokia to more closely monitor quality throughout PD phase• In PD phase, the quality often drops from B2 to B3. This can be due to process control issues at the

supplier, as well as design changes after PD2.• Ensures that the design team continues to grow their core competence• Takes advantage of suppliers tooling and manufacturing knowledge • Makes better use of Nokia resources• We can move more resources into concepting to increase the maturity of the concept

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Introduction• Mechanics Collaborative R&D (CoRD) is a new way of working with our mechanics suppliers where

we invite our manufacturing partners to closely collaborate in our PD implementation, while Nokia maintains responsibility for all the design aspects.

• San Diego mechanics team has been practicing this CoRD method in a limited scope with:• Keymat suppliers• Shield suppliers• Antenna suppliers• Mechanism suppliers

• Our goal is for the Nokia internal team to document the engineering design of the concept, in 2D and 3D, to the point where our suppliers can follow the instruction and complete the detailed design without changing the original concept.

• We believe we can extend this method to all mechanics elements, including major parts like the chassis cover assembly.

• Clearly, this method is different from previous JRD work mode. The main difference is that Nokia team assumes the entire responsibility for the design while closely collaborating with the mechanics suppliers to achieve high quality mechanics in the shortest time possible

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Goals• Improve PD execution effectiveness (reduce time from CS1 to PD3)• Improve the quality of B1 and each subsequent build• Maintaining head count while increasing the capacity• Maintain design consistency• Win together with suppliers by closer collaboration with mechanics suppliers• Improve communication between Nokia and supplier using universal “engineering”

language• Clear Ownership – CoRD assumes all the design responsibilities at Nokia side, avoiding

uncertainties and miscommunication seen previously from suppliers in the mJRD, eJRD and ODM work mode.

• Help suppliers to focus on their expertise areas (tooling, manufacturing)• Improve the Mechanics Engineering competence and Communication skills of Nokia

personnel• More Nokia personnel focused on concepting development, while suppliers are focused on

the manufacturing aspects.• Avoid unnecessary design iterations• Rapid design and tooling changes. Suppliers are very knowledgeable in design history. It

helps the tooling modification.

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VisionGeneral Nokia Responsibilities

Accurate engine architecture w/ spheres, requirements and deltas clearly documented

ID fits keep-out, size target frozen with open items identified

Space analysis (confidence on size) with no unknown problem areas. Cross section analysis for all key features.

DFA strategy, structure fixation & alignment Reliability review complete - no major issues PMQ clearly documented and agreed EM List with specification linked Long TA chains identified & justified Basic shelled parts available. Simple prototypes for

every possible part or assembly Concept history with key decisions documented Risk analysis and back up plans (May not need to

share) Identify key areas (new technologies) Lessons learned (that is relevant to the PD phase) Mechanics BOM analyzed

Roles and Responsibilities Nokia is the owner of the design Nokia to provide clear instruction for suppliers to continue the

development Nokia is responsible for all analysis, while suppliers are

supporting under Nokia’s instruction Nokia to provide clear expectations of supplier deliverables Suppliers’ resource to create 2D and 3D under clear Nokia’s

instruction and strategy Nokia is ultimately responsible for solutions Nokia clearly controls the interface of different parts that are

handled by different suppliers Suppliers’ responsibility includes manufacturing

consultations to improve the design Suppliers own the tools as well as qualification process Nokia is responsible for all Nokia key events, milestones.

Suppliers support is under Nokia’s instruction. Supplier performs specified product validation of

mechanics Nokia owns all IPRs

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Organization and Communication

Nokia Program R&D

Mechanics Project Manager

Nokia Mechanics

Team

CoRD (VI) Mechanics Lead

Supplier Team

VI Onsite Project Manager

CoRD (Supplier A) Mechanics

Support

CoRD(Supplier B) Mechanics

Support

Manufacturing

Manufacturing

Manufacturing

Each Manufacturing supplier will be responsible for their own part in this CoRD

mode.

Nokia MSM

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Examples

Nokia concepting provides detailed designs like this

For suppliers to do this

Along with – Clear expectations (deliverables, schedule, etc.)General design rationaleDFA strategyAlignment and TA mapPMQ requirementsEtc…

Along with – All CoRD related activitiesTolerance suggestions for Nokia to review" 3D model and 2D drawings creation per Nokia requirements (Q-checker, etc., 2D guideline)Support Nokia simulation file creationsRevisions as neededDocument creation per Nokia guideline, such as VQD, mechanical specification, BOM, etc.Advice if available

Referencing Mandalay ESI, supplier can use the ESI package Nokia provided and modify the 3D with supplier tooling intent and send it back to Nokia as part of the ESI feedback. In CoRD mode, it is natural for the supplier’s CoRD team to continue owning the 3D and 2D aspect of the design after ESI.

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CoRD Process Example

Nokia reviews and approves supplier’s 3d model

A problem area in design noticed and design concept with 2D & simple 3D created and communicated to the supplier for tooling feedback

Supplier send back their response with risk/concerns and proposed design concepts (in this example they sent 2 proposals)

Review their feedback and select appropriate design proposal (in this example, proposal 2 is selected)

Supplier does detailed 3d modeling per Nokia feedback or selection or design intent

SUPPLIER

SUPPLIER

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Another example of CoRD process

A Simple screen capture is often enough to communicate the design intent for suppliers to conduct the 3D modeling

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ExpectationsSupplier will provide training to their staff in both technical areas and design methodologies.

Suppliers will support Nokia to strive for perfections at each key eventSupplier’s home team are the experts in:

• Catia• Q-checker, to enable FEA simulation and ensure part quality• Manufacturing process• Nokia 2D drawing requirement

Other supplier support:• Add documentation support under Nokia's guidance, such as VQD, BOM, design

specification, etc.• Attend FOT and quick testing on manufacturing site, pre-build and pre-build testing and

provide feedback• Travel to Nokia build and support build

Supplier’s onsite PM• Good communication skills• File transfer through mICE (agreed schedule, for example, twice a week before each file

release)• Supports Nokia MSM

Design ownership• Nokia owns the design• Suppliers maintains 3D, 2D as well as needed documentations

Nokia mechanics team• Full design responsibility, including FEA

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Suppliers’ Role• Suppliers will not have the design/analysis obligations compared to “mJRD” mode.

However, supplier is highly encouraged to recommend alternate solutions. • Continue promoting the tooling trials and pre-build testing to drive for perfect B1• Focus on innovation in the manufacturing technology. • Propose alternative ways of working to improve the process even further

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Estimated Resource Savings

Current 1st CoRD (Suzuka)SavingsCS1 to B1 PM+6 PM+4 2B1 to PD2.5 PM+5 PM+2 3

 After 1st program (program for learning and establishing a clear process) Current 2nd CoRD Program Savings

CS1 to B1 PM+6 PM+3 3 (50% of engineers)B1 to PD2.5 PM+5 PM+2 3 (50% of engineers)

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Thank You!