MANUFACTURING CONTRACT TERMS OF REFERENCE

BACKGROUND (WHY)

Editor
Version

OBJECTIVE (WHAT)

STAKEHOLDERS (WHO) - RASIC

A3 Ownership before HTFB

A3 Ownership after HTFB
Sign Of
Engineering inputs
Sourcing inputs
Contract with Eng. And Purch.

VLD
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PLANT
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PROCESS - HOW : A3 FORMAT

PROGRAMME TIMING - GATEWAYS

VOLUMES, CAPACITY INSTALLED & KEY ASSUMPTIONS

MANUFACTURING PROJECT TEAM

COSTS & INVESTMENT
HPC, HPU, CPU, FREIGHT

SIGN OFF
PLANT PERFORMANCE BEFORE JOB1
LEAD PLANT

LAUNCH & QUALITY

DESIGN & SOURCING DRIVERS TO COST

AME
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NMP
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MP&L
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L. Vara

Site:
Project:

Solihull
L460

L460 MANUFACTURING CONTRACT

Version:
Update:

Owner:
Update:

dander48
Validation
6/30/2016

VLD
N.Miller

Ops. Dir
N.Bllenkinsop

PLANT PERFORMACE BEFORE JOB1

VOLUMES, CAPACITY INSTALED AND KEY ASSUMPTIONS

LAUNCH AND QUALITY

PROJECT TEAM

KEY DESIGN AND SOURCING DRIVERS TO CO

COSTS

AME Dir
G.Jones

B1

draft

AND QUALITY

SOURCING DRIVERS TO COST

MP&L Dir
D.Dyke

NMP Dir
A.Angerstorfer
LEAD PLANT

BACK TO A3

Complete

Workshop notes
Product scaleability requires buy-in
Manufacturing scaleability?
in line with stadard VPP / timing s
T&PPG scaleability
PCDS timing

stadard VPP / timing strings honoured

BACK TO A3
Year
18/19

19/20

20/21

21/22
22/23

Vehicle
L405
L462
L494
L405
L494
L460
L405
L494
L460
L461
L494
L460
L461
L460
L461

jph
vh

jph
line

Shifts

NR

32

32

32/40*

40

40 / 41*

NR

Volume
62,050
29,930
77,101
57,184
68,952
500
6,108
61,091
55,075
300
14,056
71,067
71,326
66,096
103,662

Comments:
* switch from 32 to 40jph in Feb 21 -and- 40 to 41jph
in May 2022
- PHEV / SPHEV volumes predicted to rise to c.45% of
total D7u volume

Confirm latest volumes (Lisa Bewley)

Confirm JPH vh
Session with LB

Capacity constraints more relevant - e.g. BIW Stud cell capacity / framing, etc

Subs vs Mainline
Volumes to align with the TDV's / Programme assumptions
Peak year vs Cycle average

Workshop notes
Reflect Body + nett or gross
jph vh - need Body Paint & assembly
Nameplate vs code
No of weeks per year

N.Rhodes WIP on Zonal capacity in BIW / Trim

HWD complete / check Solihull progress

BACK TO A3
KEY ASSUMPTIONS
Solihull Plant with L462 switched to Nitra. Job1
Jun20. Body Shop 2 & FA1
All facilities available at HTFB
Stamping: A-surface pressings sourced from
HWD
Body : New UN area required for turnaround in
B63/64. UP ass'y in BS2
T&F: Max facility re-use in FA1
Paint: L460 contrast roof take rate as per curent
L405 within Solihull Total capped capacity of
62K per annum. LWB capped at 25k upa
MP&L: Freight Increase from L405 due to resourcing of A-surface panels to Halewood WCE
requriement). Reduced floorspace available in
Block 63/64 due to new UN BIW facility

Overall Process desc

Site transformation r
Other projects delive

Rob Lambert

Replace overview below with new AME Progs format

Overall Process description

ite transformation requirements
Other projects delivery

ob Lambert

BACK TO A3

Re-confirm latest position with all Champ

Poss rename columes to alighn with PCD

Resources:

BODY
DCBI
PAINT
T&F Prc.
T&F Fac.
VCATS
T&PPG
MP&L
NMP
MPP
Plant Launch
Other Launch

GO/FC
G1/PS
G2/PSC
Target
In place Target
In place Target
1
1
1
1
11
1
1
1
1
1
1
1
2
1
1
1
3
3
3
1
0
1
1
1
1
1
1
1
16
2
2
2
2
2
1
1
1

TBC

NB: Not all identified above are full time. E.g. D7u SME's als

Comments / Observations
Comments: do we need all of these details?

osition with all Champions

es to alighn with PCDS

G2/PSC
G3/PTC
G4/FDJ
G5
G6
In place Target
In place Target
In place Target
In place Target
In place
11
11
11
11

1
14
2

1
18
2

1
9

1
4

me. E.g. D7u SME's also assigened to L663, etc

All AME's / Manufacturing functions
MP&L - R.Owen to advise post FDJ

G7
Target
In place
11
2

1
3

BACK TO A3
YEAR:

2020

Body
Paint
T&F
Total

HPC
Target Status
TBC
TBC
TBC
TBC
TBC
TBC
32.61 36.00

HPU
Target Status
TBC
TBC
TBC
TBC
TBC
TBC
43.20
TBC

COST PER UNIT (/unit)

Target
Status
Plant
TBC
TBC
2,153
2,301
Total Manuf.
FREIGHT (/unit)
Target
Status
Inbound (*)
906
1,020 (*) includes line feed
Outbound
306
306
Comments:
Assumes 71kpa peak volume / 63kpa cycle ave
'Unconstrained' targets to be re-confirmed

Include L405 current state

Include Benchmark

Nick Whitten
Dave Green
Jamie Cartwright

David Carruthers

Paul Longford

Add 2 columns - i) L405, ii) Benchmark + Rename 3rd column specifically for L460
Fill in L405 column prior to NM meeting

ick Whitten
ave Green
amie Cartwright

avid Carruthers

Source - Manpower Planning <FC2> submission

LV guidance
Solicit HPU info from M

Source: ??? (check S.Vasey report)

Source - MP&L <FC2> submission

aul Longford

Comments / Observations
Further work with Graham Dixon's team to confirm HPC to CPU calc / multiplication factor

V guidance
olicit HPU info from Manf Fin
Use ration / current assumption
Make point of Launch robustness (O/T inc. in HPU)

cation factor

BACK TO A3

Refresh status figures - R.Ba

INVESTMENTS
Body Construction
DCBI
Paint
T&F assembly
VCATS
MP&L
Systems (IT)
Infrastructure / PMS
Stampings (T&PPG)
Launch (NMP)
Manufacturing Total

Target Status
(m)
(m)
78.2
126.56
2.9
4.22
3.7
0.51
16.5
43.91
0.12
0.12
9.6
19.22
1.2
3.95
0.8
1.76
60
84.68
41
48.55
214.02 333.48

Comments:
- No target relief granted for additional
'Unconstrained' content
- L460 PMS included in Infrastructure

efresh status figures - R.Baller

113m targets constructed from TFLEator with Stampings switched to "F"

Comments / Observations
How do we mesure performance to compare with cost? (original L663 comment)

LV guidance
Add line for PMS
Add comment box for Target source

Body
Paint
TFA

BACK TO A3
DESIGN FOR MANUFACTURING
BODY CONSTRUCTION
Target Status
PD
Number of parts
Number of rivets (or weld.)
PD
% auto welding/rivet
100%
Meters of sealing
PD
Body variants
8
Total Body variants (other vhs)
??
Underbody commonality (%)
PD
BMV
176
187.89

N.Pitchford to lead / a

BMV Source: Manpow

PAINT
Meters of sealing
Number of colours
Contrast roof capacity (% max)
BMV

Target
48
12
30%
46

Status
48
12
30%
60

Contact R.Lambert
Also confirm current

T&F ASSEMBLY
Number of parts
Number of fixations
Utilisation
BMV Total

Target

Status

Contact R.Lambert
Also confirm current

95%
803
581

889.16
620.14

BMV Source: Manpow

Source: ??? (check S

BMV Assembly
BMV OTA
% Assembly "Golden Rules"
Complexity (Total BOM)
Comments:

BMV Source: Manpow

Include L405 current state

BIW AME & PD
Include Benchmark
X5 / Q7 / XC90
GJ - L405 to give directional L460 "best guess" directional target
When X5 / Q7 / XC90 in system later - then re-assess L460 target

AME / Nick Whitten

Dave Green
Jamie Cartwright

PD / Joe Hordyk

Add 2 columns - i) L405, ii) Benchmark + Rename 3rd column specific

Fill in L405 column prior to NM meeting

.Pitchford to lead / agree targets with PD

MV Source: Manpower Planning - S.Vasey

ontact R.Lambert
lso confirm current L405 data

MV Source: Manpower Planning - S.Vasey

ontact R.Lambert
lso confirm current L405 data

MV Source: Manpower Planning - S.Vasey

ource: ??? (check S.Vasey report)

ectional target
ess L460 target

LV guidance
(Most important sheet & most difficult)
Add comment box for Target source

Agree that Target is an output of "matched pairs" - work to

Requires development
Start with current model + benchmarks (teardo

Poss workshop with LV

Need a plan - 2/3 slides with key players / timin
DFM requires next level of planning

name 3rd column specifically for L460

matched pairs" - work together on data

el + benchmarks (teardown) + investment targets

s with key players / timing & plan to <PS>

l of planning

BACK TO
A3

Wayne Killick
Job1 Year -3
Target
Status

Job1 Year -2
Target
Status

HPU
CPU (/unit)
Divert Free Vehicles
Production Achievemnt
Build to sequence
ABS on time

Awaiting W.Killick response

Wayne Killick
Job1 Year -1
Target
Status

6th June

Job1 Year
Target
Status

Should we include:
Purely L460
All D7u
All Solihull ??

urely L460

ll Solihull ??

BACK TO
A3
LEAD PLANT KEY ASSUMPTIONS
Sole Manufacture in Solihull - no plans to internationalize L460

Complete

BACK TO
A3
List of items under discussion
FTT targets by phase
WCPA targets by phase
0 MIS warranty Launch budget
Functional and Warranty QFA
VP Parts readiness

Commodity plan readiness

Facility readiness
No of vehicle Signature features
YS/YC
Variant planning
Veh. 90% adherence to Bop/BoD

L.Vara guide
Develop list with NMP, but not regurgitate LQOS
Add specific s / key metrics which must be achieved

Q Champion: Nick Cross

L Champion: Greg Sharman

Product Coach activity in Virtual Series

Bop/BoD

BACK TO A3
DESIGN FOR LOGISTICS
Volume (m3)
Nber Assembly Stations
Assembly stations pitch
Nbre Door Line Stations
Door Line Station pitch
Engine&axels nber stations
Engine&axels stations pitch
Full BOM
MP&L BOM
Comments:

Champion Paul Longford

Target
17.2

Status
19.11

Status is based on current L405 m

TBC
2501

TBC
2793

Status is current L405 BOM part co

Source - K.Bower response 14th Ju

hampion Paul Longford

Add 2 columns - i) L405, ii) Benchmark + Rename 3rd column specific

Fill in L405 column prior to NM meeting

sed on current L405 m3 per car for Inbound Freight. Target is based on our current LEAP cost reduction targets.

rent L405 BOM part count and target is MP&L LEAP target for L460.

ower response 14th July 2016

name 3rd column specifically for L460

cost reduction targets.

BACK TO A3
SOURCING
Avrg distance to plant for m3
m3 source UK
m3 source EU
m3 source RoW
Number of suppliers
of which JIT suppliers
Comments:

Target
TBC
13.7

Status
TBC
13.4

3.5

5.7

TBC
TBC

TBC
TBC

Champion Paul Longford

Add 2 columns - i) L405, ii) Benchmark + Rename 3rd c

Fill in L405 column prior to NM meeting

Comments / Observations
VLD authorising on behalf of Purchasing / Engineering, etc
Awaiting comment from MP&L regarding TBC's
Poss need to discuss with LV for guidance on TBC's

mark + Rename 3rd column specifically for L460

BACK TO
A3
STEEL / ALUMINUM
All aluminium as per L405, inc Tailgate
lower. Mixed metals now under review
BODY PROTECTION
- Body bags assumed for 90% of vehs.

Awaiting G.Sivalingham re

MANUAL vs AUTO FACILITIES

List of key facilities to be included with
assumption of Auto or Manual.
NEW TECHNOLOGIES DESCRIPTION
SPHEV = Super PHEV. As per PHEV with
additional batteries / extended range.
MAXIMUM SIZE AND WEIGHT
Size: SWB & LWB - agreed as no greater
than the current car - Current L405 at
max cube size.
Weight: SPHEV drives higher GVM of
3340kgs. TFA assessment ongoing
Weight: Heaviest GVW (D7u) = 3340kgs
MAKE OR BUY ASSUMPTION
Assumed as per current D7u / L405

LV guide
Generic headings included

waiting G.Sivalingham response

7th June

eneric headings included - respond to each one per programme

General
A3

Indicate the key areas / departments from which the info can be sour
Guidance would be beneficial - e.g. brief user guide, with key contact
ok

Timing

ok

Volumes

ok

Assumptions

ok

Project team

Manpower Planning ommitted

Do we need all of these details? (original comment on L663 copy)
Whole people vs %ages of ?
Include area to capture the origin of the MP&L Variable target
Need assistance for HPC conversion to MCPU
Not sure where to get HPU - Manf finance?
PMS omitted
Include area to capture the financial targets origin?
How do we measure performance to compare with cost? (original com

Cost

Investments

DFMA

Plant performance

Should this include o/all Plant / overall architecture / for each assemb

Lead plant

ok

Launch & Quality

Generic statements included - tailor to suit

DFLO

"Nmbr" needs re-wording to "No of"

Sourcing

TBC's - is it feasible to avoid TBC's at <PS> ?

Need Purchasing to sign the contract

Cost drivers

hich the info can be sourced from

r guide, with key contacts & sources of info

Yes

mment on L663 copy)

L Variable target

e with cost? (original comment on L663 copy)

ecture / for each assembly hall / single model entries only -or- all ?