Sunday, October 1, 2023

New development procedure of honda car components

New development procedure of car components

Hello, in this article i will explain about the procedure of new component development of Honda. For a new model development planning is done in first priority. Accordingly activity are align at supplier end.
I have already explained in one of my article about Honda New model schedule events and activity working. Product Development Procedure |Honda Product development

Honda planning for new component development is done under an MCP.  Supplier development Activities are aligned with HCIL Manufacturing control Plan(MCP). Picture of Development planning is below:
Supplier submit TSS and Kakotora sheet before Kickoff meeting. 
TSS is Tool summary sheet, which contain information about tooling, source of tooling and tool maturation lead time. In TSS supplier give lead time for GO-1 to GO-2. (Alignment of activity to be done as per Honda Event)
With TSS we try to explain details of tool maker & Preparation timing. See below picture of TSS. 
Timing between GO-1 to GO-2  is for tool design (We say tooling design maturation).
Below is picture of TSS which is submitted by Supplier to Honda QAD.

3 Step tool GO ahead concept 

GO-0:- Tool Lead Time consensus (Agreement)

[Based on Lead Time (mention in TSS) Go1/Go2 Timing will be fixed]. Timing between G0-1 & G0-2 is for tool design.

Criteria for GO-Ahead:- As explained we will decide G0-1 & GO-2 timing on the basis supplier Lead Time. GO-1 will be a go ahead for tool design and GO-2 will be for Tool manufacturing go-ahead. Further time required to mature the tool at level T1, T2, T3 & LT1 after GO-2.  So total lead time for tool Development (tool design + tool manufacturing + tool maturation) will be different according to part categories.

For Safety part (S) lead time >150 Days
For A rank part lead time=120~ 149 days
For B rank parts lead time= 90 ~119 days
For C rank part lead time < 90 days

G0-1:- Design Go ahead

Supplier start tooling design, process design, Overall schedule, arrange tooling raw material, C/Fixture & WE jig spec sheet.
Criteria for GO ahead:- Here as I explained we do tool design side by side we also do process design in which we make PQCT-1 (process quality control table), Go ahead for GO-1 will be done after verification of manufacturability confirmation & planning. Verification of C/M taken kakotora parts is also done for GO-ahead. (To avoid any delay in actual tooling design & mfg activity, design validation & toughness confirmation must be finished before GO-1)

GO-2:- Tool manufacturing GO-ahead

We start manufacturing of permanent tools & start production of checking fixture, jigs & Equipment. 

Criteria for GO ahead:- As explained we will start manufacturing permanent tool , so we have to make overall manufacturing schedule(MCP), QA matrix before GO-2 & PAC-V Simulation & Cp & Cpk confirmation for 100% tolerance dimensions for those part which is similar to new model part. (These activities will be finish before GO-2 & verification is done for go ahead) 

Here Honda QAD checks tool maker cumulative capacity by considering other customer business. And also confirm periodic progress by photographs & 3G (3 reality principles) on regular visit at supplier end.

What are 3 REALITY Principles?

It is concept in research & problem solving. This principle instruct to:

  1. Go to the Actual place 
  2. Know the actual situation (By touching, seeing & being in contact with actual element) 
  3. Be realistic (After gaining information from actual place and actual contact one must be realistic in his assessment)

Requirement of Tool maturation level:

Question arises when we can say tool is mature enough? LT1/T4 is enough matured, well R1 is tool maturation level, which we will use for mass production. So what are the requirements to consider tool maturation level at T1, T2, and T3 & LT1/R1?

From above pictures we can see, for T1 level tool our requirements in different section is mention. Raw material requirement for T1 will be same as for M/P tools.
We can see For T1 & T2 level requirements are very limited. These level tooling can be achieved while designing (before GO-2). So we can understand now why T3 level tool is required for Proto parts of Engine related components. It is not necessary all time that we will use T1 level tool for proto based parts.

Honda Trial Events and Requirement

Part Categories/Event
Engine Part
Mission part
Frame Part
Level part Delivery
Engine/Mission endurance Test with T3 level parts, Fitment Confirmation
1. Cp/Cpk check for 100% tolerance dimensions specified on part drawing.
2. QA machine validation result & Part inspection results.
Trials for Manufacturing condition confirmation
1.Cp/Cpk check for 100% tolerance dimensions specified on part drawing (PAC-V confirmation)
2. QA machine validation result & Part inspection results.
3. Trial reports sharing of parameter study to achieve optimum mfg condition.
1.Part & Process Confirmation
2. Achieve optimum manufacturing condition.
1.Cp/Cpk check for 100% tolerance dimensions specified on part drawing. (PAC-V confirmation)
2. Optimum mfg. condition achievement & Parameter reflection in PQCT for Special Process & QA machine
3. M/P process confirmation with all quality assurance documents (PQCT/ OPS)
Final confirmation of Quality & mass production readiness.
1.Capacity confirmation (Tact Time Study)
2. All process, packing & dispatch condition same as mass production including manpower.
3. Mechanism for Change point control in mass production.
If part is related to frame components then proto event will be shoken & tool level will be T1. PAC-V confirmation will be done in Dankaku, Hinkaku & Rayokaku events, Condition for PAC-V in 3 events are different (PAC-V -Dankaku“A” rank upto 85%, PAC-V in Hinkaku –A Rank upto 95% & PAC-V A rank in Ryokaku is upto 100%).
Lot of activities are to be done in Honda new model like QAV audits, MCP & Kakotora, I am not going to explain all about it. Main purpose of this article is to explain about Process development. APQP 3rd phase is Process design & Process Development. This article will finish after understanding how we fix best parameter for part manufacturing and then we will stop.
Think at which event we will be in 3rd phase of APQP. That is Hinkaku, at this event we have to set optimum parameter of product/process in PQCT.

What is MQS/ PAC-V Deployment Process?

MQS is a document in which we summarize top symptom & control item received from drawing. It is like control document. Then we reflect those control items in MCP. Now we will check existing process assurance capability from MA Matrix.
Then we reflect important control item in process documents (PQCT-1 & PQCT-2). Finally we check Process Assurance Capability (PAC) of new part /or for similar existing part.

Method to calculate PAC-V rank

PAC-V= (Process Capability index -Cp & Cpk ) X (Process design coefficient-k)
Process Capability Index Cp & Cpk can be find out with SPC. For variable data we have to calculate Cp & Cpk and if data is attributed Cp & Cpk is based upon defect percentage.
If Defect percentage is ≦ 0.0001%, then Cp= 1.67
If Defect percentage is 0.0001% < P ≦ 0.001%, then Cp= 1.5
If Defect percentage is 0.001% < P ≦ 0.3%, then Cp= 1.33
If Defect percentage is P > 0.3%, then Cp= 1.0
Process Design Coefficient –K is depending upon detection process. 
If detection process is one time –
1. By QA Machine-Jig (k)=1.0 (If Cp & Cpk is calculated by variable data) otherwise K=1.0P , where P=  Defect %.
2. By manual Detection (k)=0.8 (For variable data), otherwise 0.8P
If detection process is 2 time-
1.  By QA equipment + Manual (k)= 1.2 (if data is variable), otherwise 1.2P
Let’s say we calculate Cp & Cpk on variable data, PAC-V will be as followed.
(1.67) x (k)
(1.5) x (k)
(1.33) x (k)
(1.0) x (k)
1.67x 1.0
1.67x 0.8
1.67x 1.2
PAC-V target is always set for A & S rank. For B & C rank –we have to take Counter measure for process improvement. Rank is decided as per below table.
PAC-V ≧ 2.0 =S
1.5 ≦ PAC-V< 2.0=A
1.2 ≦ PAC-V< 1.5= B
PAC-V <1.2 =C
Process Assurance capability talk about how much our process is capable to give us OK part without much variation. So we have to set best parameter to obtain OK part with defect percentage <0.0001%.
So we have to set best optimum manufacturing parameter, we do SPC with target to achieve PAC “A” rank & “S” rank.
So what will be process optimization methodology?
Here let’s take an example; suppose we braze two component & required spec of weld strength is more than 1200 KN. Under brazing operation process parameters will be as followed:

    1.  Heating temperature
    2.  Heating time
    3.  Cu material weight

These parameters are mostly common with H/T, Welding, Brazing, Press fit, Caulking, Torturing & Reverting. So we do trials under SPC, we very the time & temperature and make sample on these parameters and check weld strength and then we again check strength on different temp & time and so on.
See below picture for understanding:-
So we see on heating these component on temp from 800~1000 degree Celsius & for time 250 sec~350 sec.  We obtain best result. Then we can freeze best parameter for lean manufacturing. Same parameter will be reflect in PQCT for process control.

So this was about new model development of Honda and we set best parameter after studying PAC-V at each event.
All suggestion are welcome, please write to me. Thanks for visiting & Reading.


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