Download - 070301 Ifa Gtc Tour Final Eng
1iFA&GTC Tour Marc h 1, 2007
March 1st, 2007
Tadao Takahashi Executive Vice PresidentNissan Motor Co., Ltd.
Nissan’s Global Strategy
iFA&GTC Tour
2iFA&GTC Tour March 1, 2007
Nissan’s Global Strategy
Oppama Challenge
Global Deployment
3iFA&GTC Tour March 1, 2007
NISSAN 180
“Revive our company”
“Complete revival on track for
profitable growth”
“Value up with sustained
performance”Commitments
• Profitability in FY00
• Operating profit margin> 4.5% in FY02
• 50% debt reduction by FY02
• +1M units by Sep. 2005
• 8% operating profit margin
• 0 automotive debt
• 4.2M units in FY08
• Top level operating profit margin
• 20% average ROIC
Nissan Revival PlanNissan
Value-Up
Nissan’s Global StrategyFrom revival to growth and further development
2000-2001 2002~2004 2005~2007
4iFA&GTC Tour March 1, 2007
FY05 FY06 FY07
Japan
NAFTA
Europe
GOM
70 New Model Launches
Nissan’s Global Strategy
Number of start of production
1H6
2H5
1H14
2H15
1H19
2H11
Note) Just imagenot reflect actual figures
5iFA&GTC Tour March 1, 2007
Geographic Expansion (Brazil, Russia, India, China, etc.)
Nissan’s Global Strategy
Vehicle plant (Incl. KD) : 27
Powertrain plant : 25
Vehicle plantVehicle plant (Incl. (Incl. KDKD)) : 27 : 27
PowertrainPowertrain plantplant : 25: 25
KD: Knockdown plantVehicle plant
6iFA&GTC Tour March 1, 2007
Nissan’s Global Strategy
Oppama Challenge
Global Deployment
7iFA&GTC Tour March 1, 2007
Time
What is the Oppama Challenge?
: Japan
: China, Mexico, etc.
Japan-led Global Team
Production pow
er, QC
D*
* Q: Quality C: Cost D: Delivery
8iFA&GTC Tour March 1, 20 07
Company ACompany A
NissanNissan
Battles among Global Teams
Top runner
Oppama is the leader.
AB
CDE
DevelopingcountriesDevelopingcountries
EuropeUSEuropeUS
JapanJapan
AB
CDE
OppamaB
CDE
Company BCompany B
Production pow
er, QC
D
9iFA&GTC Tour March 1, 2007
Our activity of MonozukuriBreakthrough by Integration
NIMS-Friction conveyor-Strike-zone
IntegrationGenba kanri (shop floor management)-Job allocation-Ergonomics
IT-Automatic Guided Vehicle
-Simulation
iFA: integrated Factory AutomationNIMS: Nissan Integrated Manufacturing System
<Current><Before> IT-Automatic Guided Vehicle
-Simulation
NIMS-Friction conveyor-Strike-zone
Genba kanri (shop floor management)-Job allocation-Ergonomics
10iFA&GTC Tour March 1, 2007
Accumulation of Monozukuri
1960 1970 1980 1990 1994 2006
NPW start
61 Oppama64 Zama68 Tochigi75 Kyusu
83 Spain, US86 UK★創業
Integration of NPW, NIMS & V3P
★99 Ghosn management
Unique technology & expansion
Management reform & return to origin
★02 NIMS introduction
1910 1933
Foundation
★03 V3Pintroduction
★33 Foundation
Accum
ulation of Monozukuri
YoshisukeAIKAWA
V3P: New Development ProcessValue U p I nnovation of Product,Process& Program20.75 months ->10.5 months (from design freeze to start of producti on)
11iFA&GTC Tour March 1, 20 07
Nissan’s Global Strategy
Oppama Challenge
Global Deployment
12iFA&GTC Tour March 1, 20 07
Japan
UKSpain
US
MexicoProviding Know-howProviding Know-how
Up to 2004
Since 2005
Affiliates
Global Deployment
Web-typeWeb-type
Global Friendly Competition (Internal benchmarking)
13iFA&GTC Tour March 1, 2007
Global Deployment
Web-type Global Friendly Competition
UK Sunderland plantSept. 06 - US Smyrna plant
Mar. 06 -
China Huado plantMay 06 -
Spain Barcelona plantMar. 06 -
Affiliates
14iFA&GTC Tour March 1, 2007
Constitution improvement
Production trial Start of production
Support for LaunchTrial quality improvement
Global
Training
Center
Global
Production
Engineering
Center
Global
Launching
Expert
Global Package
Design
Center
3GStrategies
Global Deployment3G + 1 Strategies
15iFA&GTC Tour March 1, 2007
V3P-Digital-Network
NIMS・IBAS
GPEC
Shipping quality
Good
Aim of GPECLaunching Quality Assurance by Improving Initial Quality
Start of productionProduction trial
Production trial #3
Production trial #2
Engineering trial #1
Digital process
Before
GPEC
Integration
16iFA&GTC Tour March 1, 2007
Activities of GPECQuality Evaluation with Data & Data Transcription to Mass-production
Evaluate quality based on the data in digital phase.Evaluate quality based on the data in digital phase.
Decide conditions for good assembly parts.Decide conditions for good assembly parts.
Data, tooling and operation procedures are Data, tooling and operation procedures are transcribed to production plants.transcribed to production plants.
17iFA&GTC Tour March 1, 2007
Aim of GPDCEfficiency improvement in logistics by digitalization
Start of production
Digital package design Physical confirmation
Quality confirmation, such as vibration test
Production trial
BMPR REINF ASSY
Digital process
18iFA&GTC Tour March 1, 2007
Support initial quality control
Support trials & production preparation
Diagnose capabilityFinding
issuesSolving issues
Kaizen activities
Aim of GLE
Diagnose/evaluate preparation status & give practical support
Press Body Paint FinalAssemblyPlastic
Process
Quality analysis
Genba kanri
Vehicle quality assurance
Quality variation
Parts quality assurance
SCM/logisticsEquipment reliability
Function
Start of production Production trial
Enrolment: 764
(as of FY06)
19iFA&GTC Tour March 1, 2007
Global Master TrainerGlobal Master Trainer
Master TrainerMaster Trainer
Local TrainerLocal Trainer
OperatorOperator
Overseas plants develop “human resources” autonomously as utilizing Master Trainers.
Overseas plants develop “human resources” autonomously as utilizing Master Trainers.
Overseas plant
RTC(Regional Training
Center)
Overseas plant
RTC(Regional Training
Center)
Japan GTCJapan GTC
Possible to train 20 times faster than former direct trainingPossible to train 20 times faster than former direct training
200 people (End/2006)
20 people (as of Nov. 2006)
Aim of GTCConstitution improvement
20iFA&GTC Tour March 1, 2007
USUS
MexicoMexico
ChinaChina
IndonesiaIndonesia
ThailandThailand
South AfricaSouth Africa
SpainSpain
UKUK
JapanJapan
Global Standardization of “Training Tools”Best practices are implemented to all sites
21iFA&GTC Tour March 1, 2007
Visualized InstructionsProper procedures and key points are visualized.
22iFA&GTC Tour March 1, 2007
0
20
40
60
80
開発試作#1 開発試作#2 生産試作#1 生産試作#2
New vehicle quality evaluation
GoodModel AJapan Model A
China
Livina GenissChina
Quality Evaluation of New Vehicles in Developing CountriesSuccess of the Livina Geniss in China
Engineering Trial #1
Engineering Trial #2
Production Trial #1
Production Trial #2
23iFA&GTC Tour March 1, 2007
Nissan Production Way ~ Two never ending
Never ending quests to identify problemsand put in place solutions
Never ending quests to identify problemsand put in place solutions
Never ending synchronization (Douki) our manufacturing with the customersNever ending synchronization (Douki) our manufacturing with the customers
24iFA&GTC Tour Marc h 1, 2007
March 1st, 2007
Shohei Kimura General manager of Oppama Plant
Nissan Motor Co., Ltd.
iFA Activities in Oppama
iFA&GTC Tour
25iFA&GTC Tour March 1, 2007
What is Oppama Challenge ?World’s No.1 Monozukuri
This is the ”Survival Strategy” for the Oppama plant to recover production volume.
Through benchmarking with mini-cars and LCC* and in stronger cooperation with genba (shop floor) and engineering, we quickly “reform Monozukuri” to aim at becoming the world’s No.1 plant in terms of Quality, Cost and Time.United with internal related departments and our business partners (suppliers, logistics companies, etc.), we lead the reform to quickly communicate it to plants both at home and abroad.With this reform, we will sweep away all doubts about cost competitiveness of Japanese plants and will greatly contribute to improve the level of Nissan’s Monozukuri.
With the ”World’s No.1 Monozukuri”, we will produce global cars in order to break away from being an exclusive domestic plant.
*LCC: Leading Competitive Countries
26iFA&GTC Tour March 1, 2007
What is iFA?integrated Factory Automation
Integration of production genba & logistics
Integration of plant & supplier
Integration of IT (information technology) & genba
Integration of IT, design and production preparation
Integration of equipment fabrication & production
Integration of processes
Integration
27iFA&GTC Tour March 1, 2007
What is iFA?Smooth Material Flow + Low Cost Automation
To create the status where nothing stagnates but everything flows smoothly
as looking into material flow= Status with no waste
Introduce low cost automation.*Karakuri = automation with wisdom
* What is Karakuri?
28iFA&GTC Tour March 1, 2007
What is iFA? (examples)Smooth Material Flow
Look into material flowLook into material flow
Complex mechanism is needed, resulted in high investment in automation.
Concentrate all wastes of assembly workers to make them obvious.
<Assembly workers’operations>
- Assemble- Select & identify parts
- Walk to pick up parts
- Return empty boxes
Wastes
<Conventional operation>
29iFA&GTC Tour March 1, 20 07
Low Cost Automation
<Assembly workers’operations>
Only assembly
Consolidate material flow (1 flow line, 1 packaging style)
”Low cost automation” is realized. - Introduce AGV (automatic guided vehicle)
- Automatic transfer of containers (Karakuri)
<Kitting supply>
Possibility for automation can be expected.
What is iFA? (concrete example)
30iFA&GTC Tour March 1, 2007
iFA Promotion System in Oppama ChallengeMembers from each section and plant
<Oppama plant> Manufacturing Dept.
GenegalManager
iFAProject Team
Watanabe SVPKimura Plant Manager
ManufacturingSection
MaintenanceSection
Engineering Section
ProductionControl Section
Kyushuplant
Tochigiplant
NissanShatai
ProductionEngineering
Development
31iFA&GTC Tour March 1, 2007
iFA Kaizen Improvements in Oppama Plant(Assembly) Kitting box automatic
transfer device (Utilize existing power)(Assembly) Automatic tool up-and-down (near at hand)
(Body) P/SHELFautomatic setting
Total: 113 items<Body> Rear panelautomatic setting (fixed point supply)
32iFA&GTC Tour March 1, 2007
Global Deployment of iFA
<Global Deployment Examples>
<iFA Seminars>
Other Japanese plants (Seminar at Oppama)
UK & US (Seminar at Oppama)
Spain & Mexico (Seminar at Oppama)
UK & Spain (Follow-up at each local site)
Mexico (Follow-up at local site)
US Canton plant
Spain Barcelona
MexicoAguascalientes plant
UKSunderland plant