SAE BRASIL Congress 2013

Transcription

1 SAE BRASIL Congress 2013 Qualidade Preventiva Como alcançar um sistema robusto e competitivo. September

2 1. About Nissan; Agenda 2. Nissan Production Way ( NPW ); 3. Nissan Production Way ( 5 Behaviors ); 4. Quick Response Quality Control ( QRQC PDCA ); 5. Kaizen - THANKS Activity with Suppliers; 6. Kaizen Nissan do Brazil ; 7. Video 2

3 NISSAN IN THE WORLD

4 NISSAN IN THE WORLD Our alliances and partnerships 8.03 MILLION OF VEHICLES SOLD IN rd LARGEST GLOBAL AUTOMOTIVE GROUP SHARING PLATFORMS,FACTORIES AND COMPONENTS LUXURY DIVISION OF NISSAN RANGE FORMED BY SEDANS, COUPÉS, SUVS AND CROSSOVERS 4

5 NISSAN IN THE WORLD Global presence Operating in 200 countries 45 factories 6,000 dealerships 236,000 employees 5 design studios in 4 countries PLANT AGUASCALIENTES (MEXICO) DEALERSHIP CANOAS (RS, BRASIL) DESIGN STUDIO JAPAN Source: Nissan Global / Profile Nov`11 / Profile Mar`12 5

6 NISSAN IN THE WORLD Our Vision and Mission Vision Enriching People s Lives Nissan provides unique and innovative automotive products and services that deliver superior measurable values to all stakeholders 6

7 NISSAN IN THE WORLD Global Results in million of units sold in FY12 INCREASE OF 6.0% COMPARED TO FISCAL YEAR 2011 Net income of US$ 2.91 billion; 7

8 NISSAN IN THE WORLD Nissan LEAF Zero Emission Leadership Global sales* of electric vehicle on retail xx % xx% Nissan LEAF 71,000 units Competitors *Since sales start in Dec

9 NISSAN IN THE WORLD Nissan Power 88 Mid Term Global Plan Launched in FY 2011 and effective until FY % market share 8% operating profit by 2016 BRAND POWER SALES POWER QUALITY ENHANCEMENT ZERO EMISSION LEADERSHIP BUSINESS EXPANSION COST LEADERSHIP 9

10 BRAZIL: Land of Opportunities

11 BRAZIL Brazilian Automotive Market 4 th largest automotive market in the world Sector grew 150% in the last 9 years 2012 was the best-selling year for automotive industry, with 3.73 million registered units 3% growth forecasted for Source: ANFAVEA and Fenabrave

12 NISSAN DO BRASIL: History of the Japanese who came to stay

13 THE HISTORY OF JAPANESE WHO CAME TO STAY 1050 employees located in 6 units HEADQUARTER RIO DE JANEIRO (RJ) PLANT OF RESENDE (RJ) Starting operations 1st half 2014 PLANT OF SÃO JOSÉ DOS PINHAIS (PR) Renault-Nissan Alliance SÃO PAULO (SP) REGIONAL OFFICE JUNDIAÍ (SP) PARTS WAREHOUSE JUNDIAÍ (SP) TRAINING CENTER 13

14 THE HISTORY OF JAPANESE WHO CAME TO STAY Our history in Brazil: Nissan do Brasil foundation Start of X-Terra s manufacturing in Brazil New Pathfinder Tiida and Sentra Start of Frontier s manufacturing in Brazil 350Z s launch Murano s launch 14

15 THE HISTORY OF JAPANESE WHO CAME TO STAY Our history in Brazil: New Frontier Tiida Sedan Livina Family March and Versa 15

16 THE HISTORY OF JAPANESE WHO CAME TO STAY Our recent history Olympics Sponsorship Announcement Inauguration of structural Pillar Infiniti s arrival Announcement Announcement of Vasco Sponsorship Launch of Nissan Institute 2012 MARCH APRIL SEPTEMBER NOVEMBER 2013 Launch of Electric Taxi Project - São Paulo Launch of Time Nissan Launch of Electric Taxi Project - Rio de Janeiro Announcement of Renault-Nissan partnership with Salgueiro 16

17 RETAIL SALES & MARKET SHARE 500% of sales increase in 4 years 104,778 67,284 17,474 23,229 35, % of market share increase in 4 years 314% of market share increase in 4 years 2.0% 2.9% 1.1% 0.7% 0.8%

18 ZERO EMISSION LEADERSHIP Zero Emission Leadership Program in Brazil LEAF was the official car of worldwide repercussion events, such as C40 (2011) and Rio + 20 (2012) Electric Taxi Project: 15 units in RJ and 10 units in Sao Paulo 18

19 BUSINESS EXPASION New plant in Resende Announcement: October 2011; Investment of BR$ 2,6 billion; Annual capacity over 200,000 vehicles; 4,000 direct and indirect jobs; Start of operations: 1 st half 2014; CEO of Renault-Nissan during press conference with the Governor of Rio de Janeiro, Sérgio Cabral 19

20 BUSINESS EXPASION Legitimately green plant Rigorous Environmental Policy: To be the most sustainable Factory in Brazil; To be the No. Low Carbon footprint factory in Brazil; Ambitious goals to waste and water reduction until FY16. 20

21 THE FUTURE OF NISSAN DO BRASIL Our future goals 1 st ASIAN BRAND OF BRAZIL +200 K UNITS 5% MARKET SHARE 21

22 Plant Marquette

23 BUSINESS EXPANSION Work stages 23 March 2012

24 BUSINESS EXPANSION Work stages 24 July 2013

25 Nissan Production Way NPW

26 NISSAN WAY Action Guide of Nissan Production Way: Nissan Way Nissan Way is the mindset and actions that ensured what we have practiced, learned. 26

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28 NISSAN WAY NPW 5 Basic Behaviors 28

29 QUICK RESPONSE QUALITY CONTROL QRQC Quick Response Quality Control 29

30 QUICK RESPONSE QUALITY CONTROL Basis of Build-in Quality 1. Self Assurance by Operators - Comply with Standard Operation - Stop the Line When a Defect is Found 2. Quality Assurance by In-Line Check man - 100% Assurance of Items to be Assured 3. Final Assurance at Final Area - One-Shot Repair - 100% Assurance by Quality Team 30

31 QRQC Basic Concepts One-point Lesson Sheet Know-how sheet Build in quality - Complete tasks in a shift - 3-Gen Principle - Based on SOS (Man/Material/ Machine) Quality info input system Mfg PDCA Q R Q C Shift meeting in process QRQC mtg Carry-back meeting Modify material, machine, or method Recurrence preventions, F/B for next models Engineering PDCA (QRQE) (Kaizen plan) Activities led by Line headstream countermeasure team Change in operation Arrangement of analysis and design change Classify into man, material, machine, and method to investigate causes. Register items and assign a person. 31

32 Quality Control (QC)

33 1) Description of QC Circle - Front-line workers in shop floors - continuously control and conduct Kaizen in quality of products, services, and operations - in small groups. (1) Front-line workers in shop floors - The leader of a shop floor takes initiative in managing the activity. - Front-line workers with the leader at its center form a circle and carry out the activity.

34 Nissan Pre-World Olympics Oppama Plant (12/03/07)

35 Thanks ~Collaborative Kaizen activity with suppliers focusing on trust and harmony~ Trusty and Harmonious Nissan Kaizen activity with Suppliers Passion for this Name... This program to be thanked by each other. Build a system to promote gratitude and trust.

36 Objective & Scope Contribution for achievement of Fiscal Year parts cost reduction target by intensive kaizen through short term collaborative activity with suppliers. Promote trust with suppliers D&D, Production preparation SOP Existing Model Production EOP Service parts Production Tier3 Tier2 Tier2 Process kaizen in supplier Tier1 NISSAN Parts flow kaizen from TierN to NISSAN

37 SCOPE Concepts and Definitions THANKS SCOPE 1. Quality Loss Inspection Method. Parts Variations (Standards & Specification) Reduce Process Rejection. 2. Process KAIZEN OEE Improvement Reduce Head Count Material Handling Eliminate Stoppage Improve Lay Out Reduce Floor Area Find WTBC 3. Tier N Logistic Cost 4. Tier N Benchmark Reduce Logistic Cost at Tier N Reduce Package Cost. Improve SNP Synchronize Compare Logistic Routes & Cost Localize Process Analyze Complexity 5. Alternative Energy 6. Horizontal Deployment Reduce Energy cost through Auto Supply Society Optimize Energy Utilization Energy Process Improvements to other Plants Apply to other Process Lines Apply to other Models

38 TRANSPORTE SUPERPRODUÇÃO ESTOQUES ESPERA OPERAÇÕES INÚTEIS MOVIMENTOS INÚTEIS REFUGOS - RETOQUE S Além da eliminação de desperdícios, o KAIZEN ainda possui outros 3 propósitos: MELHORAR A QUALIDADE MELHORAR A SEGURANÇA MELHORAR A ERGONOMIA

39 Uma viagem de mil milhas deve começar com o primeiro passo. Lao Tzu

40 VIDEO