Component-related assessment of development partner

Consolidated Development Control, K-ESB

DUNS-Nr.: 652100793 Visit purpose:

Hicom Teck See Manufacturing Malaysia Sdn.Potential analysis for localization Bhd.
Lot 76 & 75A, Jalan Sementa 27/91, Section 27, 40000 Shah Alam, Selangor, VW 250 G (RL IN) Malaysia
Rating scale first development (Tier 1): A = 90 - 100% B = 75 - 89% Development capability fulfilled Development capability partially fulfilled Development capability not fulfilled

Audit Result
Component/Product Group
(with product technology)

C=

< 75%

Rating scale second development (Tier 2): incapable/capable

Part number
6RU 867 011

Assessment
First Development
(Forward Sourcing)

Second Development
(Global Sourcing)

ASSY Door Trim Armrest : >PES<

Plastic Injection moulding >PP<

74%

Capable

Findings / Requirements / Highlights / Management informations

Information to suppliers :
-Hicom-Teck See belongs to 51% DRB-HICOM and 49% Teck See Plastic. -Built in 1962 with a capital of RM260 Mil. In 2009 and 810 employees -Product Portfolio : Plastic parts (Instrument panel, bumper, door trim) -Customer : Proton, Perodua (ca. 95% Tier 1) and Brose (Tier 2) -Certification : ISO 9001 , ISO / TS 16949, ISO 14001

97 % Tier1 vs. 3 % Tier2

Management info for assessment results :

The company HTS is currently classified as a typical manufacturing / Built-to-print supplier for plastic circumferences like instrument panel without slush-OB, door trim and bumper. This company is in consideration as a potential supplier for a localization project of VW Polo G-Circumferences The company is able to produce based on customer data tools and set up appropriate production processes and carry out optimization loops Significant own development skills are lacking. CAD and CAE expertise, testing facilities and material testing. The project management is structured and based on customer specifications Other differences: see report Premise Procurement : -Support through a TE-Wolfsburg engineering services -Termination of the report illustrated weaknesses -Introducing company/technical concept in operating department TE-Wolfsburg The company was requested to eliminate the weaknesses as mentioned in the report, with a nomination by an action plan. Plant : Overview of test equipments, material safety data sheets, Chrome planning

Location information to suppliers

Corporate structure: Locations/Development locations
Main plant Shah Alam, Selangor (MY) Plastic parts Tanjung Malim plant(MY) Rayong plant(Thailand) Plastic parts for GM and Mazda 210

Products

No of Employees
648

FE

JV-Partner

23

Technical Tie-up with Marui (since 2010)

Date:

24.09.2010
Walenkamp, Gijs (K-ESB - TE-Auditor) Name, Organisation, Auditor Signature Terence SOO Thean Hin (COO) Name, Company Signature Niedenfuehr, Sven (EKKF/2)

Distributor:

Lauck, Joachim (K-ESB) Utzeri, Giancarlo (K-ES/B1) Nazare, Anja (K-ESB) Pritzke, Jens (K-ES/B1)

Poerksen, Maik (VWG Malaysia) Che, Fong Mei (VWG Malaysia) Werner, Thorsten (EKKF) Raguse, Michael (EKP/Z)

Form responsibilitiy: Volkswagen AG, K-ES TE-Lieferantenbewertung, Brieffach 1446, 38436 Wolfsburg, Deutschland Change status 01.11.2008 (A4-Format)

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Component-related assessment of development partner

Development Partner's Info
Development location(s): Contact person and position: Current Development Projects and Customers: Component or Customer Product group Proton, Perodua, Plastic parts in interior and Mazda, Honda exterior If the development partners already judged : If yes, from which supplier: Selangor (Malaysia) Sarly Adle Bin Sarkum (Head of Division Bus.Dev.)

Technology

Remarks

Experience cooperation in SE-Process Yes

Various

No Product: Middle group: Date: Rating result: Part-Number.: 6RU 867 011

Part name:

ASSY Door Trim

Judgement criteria for Project:

(Emphasis [Sum 100%]) 1. Specification and environment norm 2. Design and simulation system 3. Design capacity and skills 4. Technology und Product 5. Testing 6. Prototyping 7. Project competency/communication 8. Methods of project development (2%) (17%) (19%) (4%) (19%) (15%) (12%) (12%)

VW 250 G (RL IN)

Performance level [%]

30

40

50

60

70

80

90

100

Total Result New Product Design (Forward Sourcing)

30
Result analysis:

50
194 260*100 180

70
74%

90
C capable

Forward Sourcing
(new Product Design)

max. 260 Points reachable max. 230 Points reachable

Evaluation criteria 2.3, 4. and 8.a are not included in the assessment

Result = Result =

corresponds to Rating: corresponds to Rating:

Global Sourcing
(without new product design)

Points

Participants:

Hicom Teck See Manufacturing Malaysia Sdn. Bhd. Terence SOO Thean Hin (COO) Sarly Adle Bin Sarkum (Head of Division Bus.Dev.) Yohan bin Mokhtar (Senior Manager Veh.Man.Proj.) Lim Sheng Shun (Senior Manager Prod. Planning) Azmi Wahap (Manager Autom.Comp.&Eng. Division) Yau Kian Min (Manager Bus.Dev. Division) Adam Mat Robi (Manager Project Development) also with the participants from DRB-Hicom Headquarters

Volkswagen AG Walenkamp, Gijs (K-ESB - TE-Auditor) Poerksen, Maik (VWG Malaysia) Che, Fong Mei (VWG Malaysia)

Saw, David (VWG Malaysia) Kainz, Thomas (QS-Auditor, Audi Ungarn)

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Component-related assessment of development partner

Assessment criteria for
Requirement fully fulfilled Requirement generally fulfilled, slight deviation Requirement generally fulfilled, deviation present Requirement insufficiently fulfilled Requirement not fulfilled

Hicom Teck See Manufacturing Malaysia Sdn. Bhd. 6RU 853 651 ASSY Radiator GrilleTrim 867 011 ASSY Door 6RG
Points

6R0

807

221.D

Cover front and back

Points Points Points Points

0 5

1.

Has the development partner all the required specifications and environment standard
VW99000: available, content unknown B2B access incl. ESL available, person responsible: Project manager B2B contents should be centrally file and all involved project to be provided

2.
2.1

Design- and Simulation System

Has the development partner CAD Systems - if yes, state: Catia V5 R18 an 19: 3 Licenses
0 10

2.2

Has the development partner CAD System compatibility acc. To VW AG (VW01059) and actual System guidelines Yes, should: Catia V5 R19

20

2.3

Is the development partner using innovative Construction and Simulations method: Plastic full simulation and warping: moldflow-analysis would be performed via tools manufacturer; Documentation available

10

FE Simulation to vehicle occupant protection (ECE, FMVSS, EuroNCAP), head impact, modal analysis and acoustic (NVH), misusage: all about OEM/Customers CAE: Know-how limited availability, proposed amendment to optimise tooling come from tools supplier

2.4

Has the development partner DF (Data Transmission) and Data Check Module for drawing exchange
DF: Design data management system not available VW-compliant data check module: End check & Validity: Catia V5 R19 not available o

0 .

Datas are exchanged using CD-ROM with OEM-customer (Proton)

1. and 2. Result

(max. 50 Points)

.
0 16 24 32 40

3.
3.1

Design capacity and competency

Does the development partner possess sufficient design capacity:

Overall-design: 3Employees (CAD) / CAE: 0 Employee / Project management: 6 Employees as Programme manager plus 14 Product engineers

3.2

If 3.1 =< 24, has the development partner access/grasp to alternatives (foreign capacity):

12

16

Tools supplier (e.g Moltec, DongWang, Hanguk from Malaysia, Korea, Taiwan) IDIADA (Spain): Head impact FEM-Analysis

3.3

Does the development partner possess design competency:

10

Based on Class A-Surface-Data, component construction at OEM proton on site are performed by 3 of Hicom Teck See employees. At visited headquarters: CAD Data and drawing management / dissemination at tools supplier Employee qualification : current state matrix, without forecast CAD-Data storage needs to be improved (Stucture, partial disk, CD-Rom)
3. Result (max. 50 Points) 0 4 6 8 10

4.

Technology and Product - Does development partner possess innovation potential

If yes, for which product, process or material:

Used weld technology I-Panel:US-welding (2x), HSK: Hot-Plate welding, no laser trimming or Waterjet available, manual trimming support plate door trim Plastic: resin --> local resin supplier (see data sheet) Processes: Plactics IM, Blow Molding, no Slush or material after spraying, manual painting at location, using Robot in Thailand branch, Chrome: currently external supplier, internal facility will be establish in 2011 (micropores) 4. Result (max. 10 Points)

.
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Component-related assessment of development partner

Assessment criteria for
Requirement fully fulfilled Requirement generally fulfilled, slight deviation Requirement generally fulfilled, deviation present Requirement insufficiently fulfilled Requirement not fulfilled

6RU 867 011 Hicom Teck See Manufacturing Malaysia Sdn. Bhd.
Points Points Points Points Points

ASSY Door Trim

5.
5.1 a) b) c) d) 5.2 a) b) c)

Testing
Has the development partner appropriate test capabilities for functional testing: EP 84110.01: Push in / push out forces / Tear off test of fasteners (RT) --> external institute or OEM EP 84610.10: Function Test: load on arm rest / door tray --> external institute or OEM EP 84610.12 /EP85550.22: Buckling resistance of trim panel and door tray (RT,+70 C) EP 85550.30: Ball drop test on loudspeaker grill (M=0,5 kg RT-10 PV3905) --> external institute or OEM C, EP 85550.70: Misuse by forces up 500 N on mesh, door tray box under RT-30+70 --> external institute or OEM C Present : Gauges. Has the development partner appropriate test capabilities for continuous testing :
Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)

0 0 0 0

8 8 8 8

12 16 12 16 12 16 12 16

20 20 20 20

1 1 1 1

Block 5.1 = (Sum of a+b+c+d) / ( No a+b+c+d)

EP 84610.21: continuous load of arm rest and door handles (steel ball, 150 N, N=10000, -30+70 --> external institute or OEM C) EP 84610.50: Temperature aging +LF--> climate chamber (-30+100 C+LF, 48h) -> 1x Climate chamber (-30+177 C+LF) EP 84610.51: climatic cycle---> climate chamber (PV2005) -> 1x Climate chamber (-30+177 C+LF) EP 85550.10: Door closing Function test by pulling on tray (150N, -30+70 N=1000) --> external institute or OEM C, High temp. lightfastness (PV1303, 5 cycles, 100 CXenontest=solisi) --> external institute or OEM

0 0 0 0

8 8 8 8

12 16 12 16 12 16 12 16

20 20 20 20

1 1 1 1

5.3 a) b) c) d)

Has the development partner appropriate laboratory equipment and instrumentation:

Block 5.3 = (Sum of a+b+c+d) / (No. a+b+c+d)

Present : Dimension, Weight, Measuring table, auto. 3D measuring machine (unexact, +/- 0.1 mm). External : Flammability (TL1010) Material e.g PP : Emission behaviour, Fogging (VW 50180), density, yield stress, elongation, ball indenation hardness, melting temp. Continuous monitoring relevant : Present --> Glossmeter Checking gauge in plastic plant : Present --> Single part and Assy

0 0 0 0

8 8 8 8

12 16 12 16 12 16 12 16

20 20 20 20

1 1 0 0

Ergebnis = (Summe aus den Blcken 5.1+5.2+5.3) / (Anzahl der Blcke)

5.4

Has the development partner sufficient testing capacity: Significant amounts are performed externally

20

5.5

If 5.4 = 0, has the development partner access to alternative (foreign capacity): external Institute : e.g. TV Singapore, IDIADA, local OEM Proton

12

16

5.6

The development partner has sufficient testing competency: Present : Detailed testing plan, testing specification and documentation Present : Calibrated and documented measuring devices / no temperature controlled measuring room Gauges are used for measuring test part 5. Results (max. 50 Points)

10

0 8 12 16 20

6.
6.1

Prototyping
Has the development partner an adequately equipped and organizationally independent prototyping: Organizationally not independent. Plastic parts are manufactured on original equipment, assembly and construction prototypes in production 1 room for master sample storage Documentation as per PPAP-Document (Measuring report, test report)

6.2

Has the development partner sufficient prototyping capacity: Manufacturing and supplier for single part

20

6.3

If 6.2 = 0, has the development partner access to alternative (foreign capacity): Suppliers of component parts

12

16

6. Results

(max. 40 Points)

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Component-related assessment of development partner

Assessment criteria for
Requirement fully fulfilled Requirement generally fulfilled, slight deviation Requirement generally fulfilled, deviation present Requirement insufficiently fulfilled Requirement not fulfilled

Hicom Teck See Manufacturing Malaysia Sdn. Bhd. 6RU 867 011 ASSY Radiator GrilleTrim ASSY Door 6RG 853 651
Points
Points Points Points Points

6R0

807

221.D

Cover front and back

7.
7.1

Project competency / Communication

Can the development partners set project structures with a responsible project leader: Project teams through cross-functional teams in writing and communicated to client 0 10

7.2

Can the development partners set schedules with milestones and resource allocation and ensure the execution of changes 0 4 6 8 10

Processes and to PM clearly defined / structured customized centralized project storage at the server / schedules using MS Project Milestones customer, without critical path with filling) / Open-point list available For under development project, project rooms are set up (currently as Proton, Honda) No holistic resource planning across projects / Change Management: Process standard exists, change pass transparent and complete. 7.3 Is direct communication (without translation) possible: English 0 4 6 8 10

7.4

Is it possible to carry out a development at customer's premises Currently no Resident Engineer near Wolfsburg 7. Result (max. 30 Points)

8.

Methods of product development

Is the development partner applying the QM methods a) QFD Methods: b) Design-FMEA: c) DOE Methods: 8. Result QFD not shown in action,part of the circumference in the form of benchmarking by means of various examples 0 currently no D-FMEA (---> Built-to-print Supplier)i P-FMEA content in order including derivation process monitoring currently not implemented (max. 30 Points) (max. 260 Points) 0 0 4 4 4 6 6 6 8 8 8 10 10 10

9.

Assessment Result

Remarks
The company is requested to resolve the following weaknesses: - Study the contents of B2B-Portal (Supplier manual, norm portal, VW99000) - Ensure access to KVS - Advance their know how in terms of component design and tool-based design (plastic parts, steering wheel frame) - Advance their know how in terms of FEM-methods - Improve CAD-data storage - Implement capacity planning - Expansion of test facilities according to part testing specification (Special climate chamber, -40 C / upgrading auto. measuring machine including Scanpack / material analysis) - Improvements in production samples (space, processes, storage, workstations, packaging ...) - Advance know how product development methods (D-FMEA, QFD, DOE) The company was advised that a pro-active communication is required with the operating department The project organization (organization, contact person, position and contact information) is to be presented (including any changes) at initial project. At regular time intervals (agreed with the department) significant schedules, to-do lists and meeting of minutes should be provided. . In addition the supplier was informed that the next TE capability audits and project-specific performance rating be pronounced by the department. An improvement plan must be presented upon nomination within 14 days after receiving of this report.

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