Product development procedure of Honda car component

So supplier has to do front end loading, product feasibility along with CFT. So entire product value can be understands and an approach could be build to start development of component.

Development of each component is done as per APQP. So we have knowledge about APQP-as we know 5 phase. It could be tough for those have not worked in industries for Honda (Specially), because some event terminology and requirement could confuse fresher.

1. Planning phase 
2. Product Design
3. Process Design  
4. Product/process Validation
5. Feedback , Assessment  & Corrective action

Obviously development will be done as per APQP, but customer events & requirement could be specific. So we have to know those specific requirements as well as we have to know how to work as per those events.

Generally business is awarded on the basis of supplier selection after tech review meeting with customer. Sometime suppliers are selected after lot of review meetings.

OK let’s say- Your Company is identified as possible source of supplier for an OEM (HONDA).

OEM will release RFQ and will request quotation.

Supplier checks feasibility and confirm with quotation. If customer find that deal OK as per comparison with other supplier.

OEM issue LOI and request for Proto based parts. And if trial OK, preparation will be done for mass production. After all successful trials in development phase –Mass production is started. Supply is continuing at OEM on regular basis.

This was short description “How parts are development” but this is not simple as it seems, lot of work is done to bring any component in mass production successfully.

So here we will understand that process in details:-

Here I will take HONDA as OEM (The customer). Well we know what Honda do- Makes cars, many automotive works.

Vehicle Body parts:- see below picture 

1. Mision parts
2. Engine parts
3. Frame parts

Above three categories of parts are further classified in A, B, C & S ranks.

A – Critical to Quality, S – Safety part.

There are many categories, apart from these other categories are:- Electrical parts, chassis parts, Equipment, standard and semi standard parts, Body parts.

Now before going to direct development, we have to understand customer drawing. Basically drawing vary customer to customer, in Honda case they provide special symbols and abbreviation.

Understanding Honda product drawing

Double crossed line, show that symbol is not applicable for this part.

First 2 symbols from left side are -GRADE-1 & 2 To Judge General Tolerance on Dimensions.
Rest 3 Symbols are for TOLERANCE CLASS INDICATION (HIGH, MEDIUM, and LOW ACCURACY) AS PER HES A2135-99.

Title Blocks of HONDA product Drawing

What are Honda Part category?

1. HS:- Safety part [PARTS WHICH LOSE IMPORTANT FUNCTIONS & MAY CAUSE SERIOUS ACCIDENTS WHEN FUNCTION FAILURE OCCURS ]
2. HA:- PARTS WHICH LOSE IMPORTANT FUNCTIONS & MAY RESULT IN SERIOUS ACCIDENTS WHEN FUNCTIONAL FAILURE OCCURS, BUT WHICH SHOW SOME SIGN SO THAT SAFETY PRECAUTIONS CAN BE TAKEN.
3. HB: – PARTS WHICH LOSE IMPORTANT FUNCTIONS WHEN FUNCTIONAL FAILURE OCCURS DO NOT RESULT IN SERIOUS ACCIDENTS.
4. H:– Other than above

1. PP –Proto part
2. MPP- Mass production part
3. PILOT-Verification of mass production condition
4. SOP-Start of Production

1. E-Dan & M-Dan
2. Dan Event
3. Dankaku Event
4. Hinkaku Event
5. Ryokaku Event

E-Dan even for Engine part only.  M-Dan is for mission part only. Dan, Dankaku, Hinkaku and Ryokaku events are for CBU.

A000=PLANNING PROPOSAL BY CST TEAM

A001=DEVELOPMENT INSTRUCTION, CONCEPT/BASIC DESIGN APPROVAL

P1=PLANNING INTIATION AND MODEL FIX- DRAFT PLANNING

A000; A001; P0, P1 these activities are done at Honda Company. Up to P2 Honda finished planning, now moving to Proto part making. So accordingly they will make development plan and will share RFQ to supplier.

1. MCP CHECK (Shoken: T1)
2. TOOLING PLAN
3. INSP FIXTURE CONCEPT
4. SPEC TEST PLAN
5. KAKOTORA & MQS
6. HOMOLOGATION PLAN
7. OEE PLAN CHECK
8. CONCERN (If Any 

1. MCP REVIEW
2. TOOLING COMPLETE
3. INSP FIXTURE APPROVAL
4. R/ MATERIAL APPROVAL
5. EQUIP. PROGRESS CHECK
6. PACKAGING SAMPLE SUBMIT
7. HOMOLOGATION CERTIFICATE

1. PART CHK AS PER EVENT TGT
2. FITMENT CONFIRMATION
3. QA M/C VALIDATION AS PER CHK-SHEET (L/TEST & WELDING)
4. MIN-MAX STUDY OF PROCESS PARAMETERS (FOR SPECIAL PROCESS)
5. CONF. OF PAC-V, KAKOTORA, ETC
6. PQCT APPROVAL
7. LIMIT SAMPLE FREEZE
8. SPEC TEST REPORT CONF
9. M/P READINESS CHK

1. MCP REVIEW
2. R1 TRIAL EVALUATION
3. Cp / Cpk VERIFICATION (100% PAC-V A RANK)
4. M/P READINESS EVAL.
5. PACKING/IDEN. CONFIRM
6. PROCESS TACT VERIFY
7. MANPOWER TRG.COMPLETE
8. Safety Declaration (ANGEN SANGEN)

Honda QAD handover these documents to Mass Production team, [(PQCT, INSPECTION  STANDARDS, LIMIT SAMPLES, TEST RESULTS, CAPACITY SHEETS, LOT CONTROL SHEETS, PACKAGING STANDARDS].

1. Production Preparation
2. Finishing Quality of product
3. Standards
4. Education and training
5. Quality Strategy
6. In process Quality Control
7. Control at suppliers (Tier-2, 3)

• Air Circuit Diagram for AIR FLOW IN DIESEL ENGINE:-

• DIAGRAM FOR COOLANT FLOW IN DIESEL ENGINE:–

• DIAGRAM FOR FUEL FLOW IN DIESEL ENGINE:-