Professional Documents
Culture Documents
PRACTICAL
PROJECT
MANAGEMENT
(BLB10053-2-PPM)
By:
Lahiru Dilip Jayampathie
(CB003121)
HF1041BA
BA (Hons) Business Administration
Instructor:
MS. Hemamali Thennakoon
Executive Summary
This report would contain the information about the new development of D9 which is estimated
to become a hit in the near market. The car will be named as the Suzuki d9 and it’s expected to
carry a tag line “the fastest and most affordable sport sedan in the history of the automobile
industry” what’ll enhance the requirement of such machine.
Many aspects will be looked around like luxury, greater performance in the meantime the fuel
economy carries a major weight and will be the significance of this car. The D9 will fulfill what
the world is missing for quite some time as many super cars or sport cars are born with heavy
price tags and suffering fuel economy as they empty their containers in seconds. As Suzuki
Motor Corporation we addressed this issue and will work on to make reality for the dreams of
the customers.
The project is estimated to take 1 year for the completion and 1500000$ budget and will test the
skills of 556 of our best employees. The project is carried out in the factory in America and a
new plant will be put together especially for what’ll become our flagship vehicle. The company’s
corporate group which consists of 147 subsidiaries and 37 affiliations makes Suzuki Motor
Corporation a market giant who always comes up with revolutionary innovations to enhance the
lives of our customers
Mission: “Safety of our customer, take environmental conservation into consideration, obey all
laws, regulations and social rules and maintain good relationships with our individual
stakeholders as members of society”
Vision: The Leader in the Automobile Industry, Creating Customer Delight and Shareholder's
Wealth.
Table of contents
Contents
Executive Summary.....................................................................................................................................2
Table of contents.........................................................................................................................................3
List of Tables................................................................................................................................................4
List of Figures...............................................................................................................................................5
Abbreviations..............................................................................................................................................6
Project Charter............................................................................................................................................7
Project Justification.................................................................................................................................7
Project Purpose.......................................................................................................................................8
Project Scope...........................................................................................................................................8
Assumptions, Constraints, Dependencies................................................................................................9
Goal and Objectives.................................................................................................................................9
Project Deliverables...............................................................................................................................10
Milestones.............................................................................................................................................10
Project Stakeholders..............................................................................................................................11
Project Organizational Structure...........................................................................................................12
Terms of Reference...............................................................................................................................13
Baseline Plan.............................................................................................................................................28
Resource Requirements............................................................................................................................31
Risk Plan....................................................................................................................................................35
Quality Plan...............................................................................................................................................39
What is quality meant to the company?................................................................................................39
Exhausting challenge for the project team............................................................................................39
Evaluation of quality in terms of business perspectives........................................................................40
Evaluation of quality in terms of the vehicle.........................................................................................41
Quality plan for Suzuki D9.....................................................................................................................43
Quality improving initiative of the company.........................................................................................46
Change Plan...............................................................................................................................................47
Objectives of change plan......................................................................................................................47
Role descriptions for the change management process........................................................................48
Change management process...............................................................................................................49
Communication Management Plan...........................................................................................................50
Target Audience....................................................................................................................................50
Communication Method........................................................................................................................50
Communication Events of the Project...................................................................................................53
Project Conclusion.....................................................................................................................................54
Bibliography...............................................................................................................................................55
References.................................................................................................................................................56
Appendices................................................................................................................................................57
List of Tables
Table 06- Illustration of the desired out comes expected through quality principles
056
056
Project Justification
The efforts will be put together to build the fastest and economical sport sedan in the history with
a street driven legality tag. Many aspects will be looked around like luxury, greater performance
in the meantime the fuel economy carries a major weight and will be the significance of this car.
The D9 will fulfill what the world is missing for quite some time as many super cars or sport cars
are born with heavy price tags and suffering fuel economy as they empty their containers in
seconds. It left the people with fairytales where it was only in dreams that an average person
could own a true power house.
As Suzuki we addressed this issue and it would not be only in thoughts that the people will have
a super car which will fulfill not only the thirst for speed but also the convenience of a family
holder. The D9 will be equipped with a powerful as well as economical 4.2 liter twin turbo
charged V8 engine that delivers 660hp and 550 lb-ft of torque at a greater fuel economy.
(Refer appendix c)
Project Purpose
The main purpose of this project is to address the above mentioned issue and at the same time
gain access to the untapped market. The company aims to gain more market share and will
expect to be a hit in the market and be the flagship vehicle of the company.
Project Scope
Scope Definition
The scope of this project would be to build the fastest and most affordable sport sedan which
will deliver 660 hp at an average top speed of 360 Km/h. The project should be carried out with
in a period of 1 year at an estimated budget of 1050000 $. The car should be providing seating
for 5 people and a minimum mileage of 10 Km/L.
Project Goal
The intent of this project is to put together a car that can break the speed limits while delivering
greater fuel economy. The affordability is one of the significant factors which are married to the
main intention.
It’s to address the middle class speed enthusiasts who look for a super car that break the speed
shackles at the same time which can fulfill the desires of a sedan. With the development of
Suzuki’s D9 the problems will be wiped out and the car will only be missing is a royal price tag.
Objectives
Timely completion of the project (271 Days)
Keep up with the allocated budget ($1,367,706.04)
Always keep up with the pre determined quality standards, procedures. (Defined in
quality plan)
Project Deliverables
Deliverables
The engine that generates massive power which will result in greater speed.
Light weight strong chassis which aids for greater fuel economy and added safety of
the passengers.
Cut down the unnecessary work processes and use of materials to achieve reduced
price.
Luxury interior for added comfort and smooth journey.
Develop all-wheel drive system which transfers power precisely for added handling
and greater fuel economy.
Use of Nano technology to cut down prices and superior quality.
Develop 7 speeds Manu-matic transmission to achieve best speed from power
generated from the engine.
Milestones
Project Stakeholders
1. Project Stakeholders
Functionality Name Role
CEO, Suzuki Motors Osamu Suzuki Project sponsor
Project Manager Lahiru Dilip Supervisor, approver, responsible
Product engineer (3) Ruchith Jayathilaka, Responsible for design and test of
Hatchiman, Kimu lee
components
Development engineer Lahiru Kannangara, John Engineers the attributes of the car
(3) Howard, Jay Sean
Manufacturing Paul Sean, Thusitha Aids production of components
Engineer (2) Pushpakumara
Quality assurance John Sean, Pasidu Review the quality of each component
team (4) weeraman, Sajith Ruwan,
and check for production defects.
Ohu Takatsuka
Problem identification James bond, Osuki Suzuki, Identify existing problems, gaps and
team (3) Charles Shane
take corrective action.
Employees (540) Responsible for the production and
assembling of the car
Terms of Reference
Responsibility
WBS Project office
CEO PM PIT QAT CFT PE DE M S PP ALE R LS
E E
Planning (Problem identification & Feasibility Study
Requirements ▲
Analysis
Recommended ▲
Approach
Cost/ Benefit ▲
Evaluation
Final Review ▲
Approval ○
Analyze the ▲
existing
employees for
related
competencies
Evaluate the ▲
experience in
work in the
company
project team
Approval of the ○
project team
Research and development
Design elements/ Development Process
Exterior design ▲
(Outer
appearance,
dimensions)"
Interior design ▲
(Interior
dimensions,
appearance,
placing of
equipment)"
Color and trim ▲
design
Graphic design ▲
Finalize design ▲
elements
Design chassis ▲
suspension
(Designed with
KYB)
Design braking ▲
system
Powertrain ▲
engineering
(engine)
Manumatic ▲
transmission
Lighting design ▲
system
Electrical ▲
engineering
Smart keyless ▲
entry
Manufacturing ▲
process design
Design review, ▲ ▲ ▲
Quality
assurance"
Approval
Put up the ▲
assembly line
Build the ▲
computer of the
car
Build front ▲
windscreen
Build rear ▲
windscreen
Build the hard ▲
top
Build front ▲
bumper
Build rear ▲
bumper
Build spoiler ▲
Build side ▲
impact door
beams
Build doors ▲
Build glass ▲
shutters
Build side ▲
mirrors
Build electrical ▲
components
(Circuits)
Finalize ▲
electrical wiring
(Combine
circuits, power
cables)"
Build dash board ▲
Build ▲
instrumentation
panel
Build switches ▲
Build all-wheel ▲
drive system
Build the vehicle ▲
transmission
Build exhaust ▲
system
Build the ▲
compressor
Build the ▲
condenser
Build the ▲
evaporator core
Build chrome ▲
platted aluminum
rims
Build motors for ▲
sheets
Build smart ▲
keyless entry
system
Finalize sheets ▲
Build the ▲
radiator
"Build Suzuki ▲
Build intake ▲
manifolds
Build Exhaust ▲
manifolds
Build push start ▲
ignition
Build push start ▲
ignition
Deliver the ▲
sheets to the
upholstery shop
Deliver other ▲
pan
Build rear ▲
compartment
Putting up the ▲
chassis (welding
by a robot)
"Install sound, ▲
Reinforce ▲
welding work by
human
top
Attach doors to ▲
the body
Attach metal ▲
body panels
(front, bonnet,
and luggage)"
Deliver the ▲
chassis to the
paint shop
Body wash shell ▲
to remove dirt &
grease
Blow dry to ▲
remove lingering
dust
Paint bath ▲
Body wash to ▲
remove excess
paint
Drying ▲
Apply interior ▲
paint by human
Apply exterior ▲
paint by robots
Paint dry-out ▲
(170 C)
Apply unique ▲
out (160 C)
pistons
Build the ▲
cylinder block of
the engine
Build cylinder ▲
head of the
engine
Build the gasket ▲
control module
▲
Build engine
bearings
Build starter ▲
motor
Build electronic ▲
spark controller
Build crankshaft ▲
Build engine ▲
airflow sensor
Build crankcase ▲
Install bearing to ▲
Install first 4 ▲
pistons to the
crankcase
Install crankshaft ▲
to the crank case
Link the pistons ▲
to the crankshaft
Install the second ▲
part of the
crankcase by a
robot
Install the ▲
remaining 4
pistons to the
crank shaft
Crank the engine ▲
by human
Cylinder heads ▲
are placed in to
the engine
Install variable ▲
valve timing
system
Install the valves
of the engine
Install the oil ▲
Install the ▲
ignition system
Install the ▲
electronic spark
controller
Install intake ▲
manifolds
Install the ▲
airflow sensor
injectors
Install electronic ▲
throttle controller
Install exhaust ▲
manifolds
control module
motor
Computer ▲
assisted engine
check
Deliver the ▲
engine to the
main assembly
line
Check the lather ▲
for flaws
Take the ▲
measurements
using a laser
beam
Cut leather by ▲
machine
Stitch the cut ▲
parts
Apply glue to ▲
stitch parts
Worker attach ▲
leather to the
dash board
Make out sheets ▲
Upholster ▲
steering wheel
Deliver ▲
Upholster items
to main assembly
line
Assemble the Vehicle
Electrical wiring ▲
Install power ▲
steering lines,
pedals, water
lines
Install fuel tank ▲
Install dash ▲
board and
Speedo meter
Set up ▲
transmission to
the engine
Add fuel lines, ▲
belts, wires and
heat shields"
Attach engine to ▲
the body
lubricators
Put up the
exhaust system
Install the all- ▲
wheel drive
system
Place the ▲
electromagnetic
shock-absorbers
Install rear ▲
bumper, tail
lights, and boot
Attach wind ▲
screen by robot
Attach rear wind ▲
screen by robot
Attach rain ▲
sensing wipers
Install battery, ▲
front bumper,
steering wheel,
and airbags
Install key less ▲
entry system
Install the sound ▲
system
Install seats ▲
Install spoiler ▲
Install head ▲
lights
Put in required ▲
"Check vehicle ▲
braking, speed,
steering"
"Test prototype, alternations & review"
Front crash test ▲
Proper working ▲
of air bags
Proper working ▲
of seat belts
Vehicle braking ▲
distance
Electronic ▲
stability system
Performance ▲
Top speed ▲
Acceleration ▲
Road handling ▲
Drivability ▲
Durability ▲
Functionality of ▲
the systems
Mileage ▲
Wind tunnel test ▲
Vehicle ▲
dynamics
Make ▲ ▲ ▲
improvements if
required
NHSTA vehicle ▲
approval
Training ▲ ▲ ▲
employees
impression about
the car
Press releases to ▲
make customer
awareness and
differentiate thee
product
Build ▲
anticipation
through
advertising
Testing on the ▲
success
First car launch ▲
in the most
potential market
(Auto show in
USA))
Start the ▲
Production to
meet the demand
/c
6
2
a
d
1
$
0
7
D
je
o
9
,3
.4
Task
y
s
Assembly Line Employees
Planning,
problem
identification
and
feasibility
study
Start Date
6/1/2010
Formation of 6/14/2010
project team
Research and 6/24/2010
development
Table 03 – Responsibility chart
Baseline Plan
End Date
6/12/2010
6/22/2010
2/24/2011
Duration
(days)
11
179
Cost
($)
30,000
24,000
705,840.00
Type of
Relationship
Sequential
Sequential
Sequential
Dependency
2
Build body 2/25/2011 2/25/2011 1 44,749.25 Sequential 3
parts
Design elements
Errors in estimating
time, cost and poor High Somewhat likely Quality assurance team and problem
resource allocation. identification team will run a thorough
Lack of quality in analysis and solutions will be made.
design. Design is Design can be changed as required.
incapable of achieving
required target.
Development Process (refer WBS)
The elements are Some aspects like fuel economy can
incapable of achieving High Somewhat likely be compromised lightly to reach
actual target expected power.
Manufacturing process design & Assembly line
Poor allocation of Review the assembly strategy more
time, people and Medium Likely than once. Continuous and timely
activities. Equipment servicing of machinery. Have backups
defects in the as required
assembly line
Design review, Quality assurance
Lack of quality High Unlikely It’s reviewed according to the
project preview, requirements and quality plan and it’s
missing of key unlikely of occurring
activities, design
review errors
Approval
Granting of approval High Somewhat likely The requirements are defined clearly
or Rejection up front. Terms of reference and
quality plans will indicate who is
responsible, what should be done and
according to what it should be done.
The body shop
Preciseness of body High Unlikely Each and every part will be checked
parts, Timely for quality, accuracy and preciseness.
completion and errors Workers are given an extensive 3
of work. months training on area which they are
responsible.
The paint shop
Flaws of the paint Medium Unlikely Work is carried out by robots where
work the preciseness is needed and where
the errors can occur.
The engine shop
Defects in the parts High Somewhat likely Engine is checked at the engine shop
used in the engine, first by a mechanic and then using
Faulty assembly of computers for errors.
the engine
Upholstery shop
Stitch work is not Medium Likely Workers are given a extensive training
precise. Usage of and only experienced people are given
wrong material the job.
Main assembly line
Faulty assembly of High Unlikely Each and every assembly of parts are
parts, Parts getting checked by a supervisor. Assembly
damaged while station workers will be familiarized in
installation the work through training using
prototype assembling.
Testing
Tests are formed Medium Unlikely All the testing elements and
inefficiently procedures are clearly defined up
front. Use advanced machinery and
techniques in testing. Internationally
recognized testing principles are used.
As Suzuki Motor Corporation, we value our customers’ perspectives and delivering customer
satisfaction is our top most priority through superior products and after sales service to match
with the customer requirement. To achieve our goal verification and validation is done and each
of our products will undergo extensive inspections and testing at each level. The fatiguing task of
the development of D9 is to live up to the expectations together with the perceived quality.
Integrated manufacturing quality & Deliver the product in line with the design
vehicle launch process specifications all the time.
Table 06- Illustration of the desired out comes expected through quality principles
1. Project completion on time- The timely completion of the project is regarded as a quality
aspect by keeping up with the deadlines. The timely developments of the design
requirements, efficiency of the employees and adhering to the guide lines are critical and
achievement of those will determine the quality of the project.
2. Completion of the project within the budget- It should not be exceeding the budget,
nonetheless it’s allowed to go beyond the budget due to unavoidable circumstances such as
increase of the prices of raw materials or taxes yet shouldn’t exceed the buffer amount.
3. Did it achieve company objectives- The product must comply with the prospects of the
company through achieving the expected performance, and outlook what’ll help company to
attain desired sales of 150,000 units in the first year.
Note: (*) Indicates the work will be carried out by the workers in the production stage of the car
(€) Indicates the work will be carried out by the engineers at the prototype stage
1. Through customers perspectives- Quality always starts from the customer perception
and customer’s feedback and critical issues will be gathered through 24 hour customer
service centre and forwarded to the quality assurance and problem identification teams
for improvements.
2. Through staff training- Staff will be trained in order to determine the likely problems
that the customers may have in their minds and act according to the situation when
there is a service quality issue.
3. Through continuous tests- Quality will be improved through actual road tests, by
customers’ feedback, virtual simulation tests at the company where the vehicles
undergo a different environmental condition test.
4. Quality assurance test- A sample of vehicles will be tested for the preciseness of the
measurements and functionality of the systems to make sure the production quality will
remain same in every vehicle.
Change Plan
Change management plan will help the project manager to control and monitor the project
changes. The change is identified as any activity that would change the scope, deliverable, cost
or schedule of the budget. When a change is identified it should be forwarded to the project
manager for the evaluation and it’s the responsibility of the project manager make any
alternations or disregard the request depending on the impact it has on the success of the project.
Objectives of change plan
o Identify changes in scope, or other unplanned activity, in advance and control them.
o Resolve any questions or issues that may surface between vendors and the project team
regarding scope and/or project deliverables outlined in the Statement of Work (SOW).
o Ensure that new tasks and other requested changes are justified, and that affected
deliverables are identified and modified accordingly.
o Obtain authorization to proceed with the changes and assign them to appropriate
individuals to be completed.
o Monitor the progress and cost of the changes.
Role Description
CEO
Facilitates the change if it’s worth and approved by the project
manager. Mainly facilitates the budget requirements.
Project manager
Evaluate the potential change and identify the impact it has on the
success and if it hinders the accomplishments approve expected
change and inform the project team about the change.
Product engineer
Facilitate the change by actively participating
Development engineer
Identifies likely product alternations depending on the scope
(requirements like speed and mileage) of the project and inform the
project manager and the manufacturing engineer for alternations in
the process.
Manufacturing engineer
Make alternations in the production of the parts and systems
according to the development engineer.
Employees
Act according to the regulations provided by the engineers.
Problem identification
Inform the project manager about the existing problems and gaps.
team
Disseminating knowledge and information about the project is critical for its success or failure.
Hence the people who are engaged in the project will demand knowledge about the current
situations, achievements, failures if any and its consequences. The success rate would depend on
how well the people are educated and will include informing, linking and obtaining feedback
from the project team. .
Target Audience
Communication Method
Top- Down communication- It starts from the project manager who will
communicates about the requirements for the project team. It’ll always follow a
hierarchy in which the information about the project will flow from the top to its
bottom.
Figure 03- Information Flow Hierarchy
Bottom- Up Communication - It’s a must to ensure that the information is gathered at each
level for the success of the project. It starts from the bottom line workers as they are directly
engaged in work units and practicality problems, gaps and issues can be identified. Then it’ll
be forwarded up in the hierarchy for solution and alternations. It should make sure that the
feedback will return soon in an effective manner for the work to be successful.
Design will be evaluated in terms of the objectives and international regulation and
it’s approved the requirements and the information about the actual design will be
disseminated across the project team.
Monthly meeting
The project manager will conduct a monthly review meeting with the Engineers,
quality assurance team and the problem identification team to
Address issues
He’ll inform the CEO about the current progress and all the project members will be
issued a summarized report informing about the current situation, schedules and
alternations if any.
Project Conclusion
The project will be expected to finish successfully achieving the goals of the company and the
company will receive several benefits via D9. The project will be carried out solely by the
company engineers and workers what’ll help gain extra payments and experience and be part of
a team that changed the history of automobile industry. The work will be assigned for 555 of our
best employees of the company and the internal process will reduce communication problems
and help the controlling of the project.
One of the tormenting factors would be the scope itself as it pushes the skills of our employees
and the technology to its limit. There can be lot of technical problems that has to solved to
successfully put up the car and it’ll require preciseness to go along with the knowledge of our
project team to make the dream of D9 a success. The time estimates can always make life
difficult for the project team, yet is needed to adhere to the determined time scales.
One of the major issues can be the labour absenteeism as it’s hard to predict the nature of the
human lives. There can be absenteeism due to illnesses, marriages or even due to deaths and in
that situation there would be a huge impact on the success of the project. To overcome this issue
there is always buffer period allocated for each activity to avoid such situations.
Budget cannot be overrun in any situations unless an unavoidable incident occurs and in these
situations an extra budget is only allowed upon approval of the project manager and the CEO.
References
Mr Ashley Emerson, The Launch jaguar xk7 Sports Car [Online] Available:
http://www.jagular.comhtml [Accessed 28 April 2010]
1 Project D9
1.1 Planning (Problem identification & Feasibility Study
1.1.1 Define the scope
1.1.2 Requirements Analysis
1.1.3 Recommended Approach
1.1.4 Cost/ Benefit Evaluation
1.1.5 Final Review
1.1.6 Approval
1.2 Formation of Project team
1.2.1 Analyze the existing employees for related competencies
1.2.2 Evaluate the experience in work in the company
1.2.3 Check for the past performance of the selected employees
1.2.4 Finalize the project team
1.2.5 Approval of the project team
1.3 Research and development
1.3.1 Design elements
1.3.1.1 " Exterior design (Outer appearance, dimensions)"
1.3.1.2 "Interior design (Interior dimensions, appearance, placing of equipment)"
1.3.1.3 Color and trim design
1.3.1.4 Graphic design
1.3.1.5 Finalize design elements
1.3.2 Development Process
1.3.2.1 Design chassis
1.3.2.2 "Tires, Rim size, Wheel base"
1.3.2.3 Design suspension (Designed with KYB)
1.3.2.4 Design braking system
1.3.2.5 Powertrain engineering (engine)
1.3.2.6 Manumatic transmission
1.3.2.7 "Lighting design (Head lights, Tail lights, Fog lights, Signal lights)"
1.3.2.8 Entertainment system design (Designed by Rockford Fosgate)
1.3.2.9 Vehicle air conditioning
1.3.2.10 "Vehicle instrumentation design (functionalities, drivers’ information systems)"
1.3.2.11 Vehicle navigation system
1.3.2.12 Electronic stability control system
1.3.2.13 All- Wheel drive system
1.3.2.14 Electrical engineering
1.3.2.15 Smart keyless entry
1.3.2.16 End of development process
1.3.2.17 Manufacturing process design
1.3.2.18 "Design review, Quality assurance"
1.3.2.19 Approval
1.3.3 Put up the assembly line
1.4 Building the Prototype
1.4.1 The body shop
1.4.1.1 The parts Shop
1.4.1.1.1 Build the computer of the car
1.4.1.1.2 Build front windscreen
1.4.1.1.3 Build rear windscreen
1.4.1.1.4 Build the hard top
1.4.1.1.5 Build the metal bonnet of the car
1.4.1.1.6 Build the metal boot of the car
1.4.1.1.7 Build side panels
1.4.1.1.8 Build front bumper
1.4.1.1.9 Build rear bumper
1.4.1.1.10 Build spoiler
1.4.1.1.11 Build side impact door beams
1.4.1.1.12 Build doors
1.4.1.1.13 Build glass shutters
1.4.1.1.14 Build side mirrors
1.4.1.1.15 Build electrical components (Circuits)
1.4.1.1.16 "Finalize electrical wiring (Combine circuits, power cables)"
1.4.1.1.17 Build dash board
1.4.1.1.18 Build instrumentation panel
1.4.1.1.19 Build switches
1.4.1.1.20 Build all-wheel drive system
1.4.1.1.21 Build the vehicle transmission
1.4.1.1.22 Build exhaust system
1.4.1.1.23 Build the compressor
1.4.1.1.24 Build the condenser
1.4.1.1.25 Build the evaporator core
1.4.1.1.26 Build chrome platted aluminum rims
1.4.1.1.27 Build motors for sheets
1.4.1.1.28 Build smart keyless entry system
1.4.1.1.29 Finalize sheets
1.4.1.1.30 Build the radiator
1.4.1.1.31 "Build Suzuki badge, logo, car name"
1.4.1.1.32 Build intake manifolds
1.4.1.1.33 Build Exhaust manifolds
1.4.1.1.34 Build push start ignition
1.4.1.1.35 Build touch screen navigation system
1.4.1.1.36 Deliver the sheets to the upholstery shop
1.4.1.1.37 Deliver other body parts to the main assembly line
1.4.1.2 Building the chassis
1.4.1.2.1 Build the engine compartment
1.4.1.2.2 Build midway pan
1.4.1.2.3 Build rear compartment
1.4.1.2.4 Putting up the chassis (welding by a robot)
1.4.1.2.5 "Install sound, spark and glare shield"
1.4.1.2.6 Reinforce welding work by human
1.4.1.2.7 Make screw halls by robots
1.4.1.2.8 Laser check of the chassis
1.4.1.3 Install the hard top
1.4.1.4 Attach doors to the body
1.4.1.5 "Attach metal body panels (front, bonnet, and luggage)"
1.4.1.6 Deliver the chassis to the paint shop
1.4.2 The paint shop
1.4.2.1 Body wash shell to remove dirt & grease
1.4.2.2 Blow dry to remove lingering dust
1.4.2.3 Paint bath
1.4.2.4 Body wash to remove excess paint
1.4.2.5 Drying
1.4.2.6 Apply interior paint by human
1.4.2.7 Apply exterior paint by robots
1.4.2.8 Paint dry-out (170 C)
1.4.2.9 Apply unique body color coat by hand
1.4.2.10 Finale paint dry-out (160 C)
1.4.2.11 Apply clear coat by robots
1.4.2.12 Remove the doors
1.4.2.13 Deliver the doors to the upholstery shop for finishing
1.4.2.14 Deliver the finished body shell to the main assembly line
1.4.3 The engine shop
1.4.3.1 Build the engine parts
1.4.3.1.1 Build the pistons
1.4.3.1.2 Build the piston rings
1.4.3.1.3 Build piston connecting rods
1.4.3.1.4 Assemble the pistons
1.4.3.1.5 Build the cylinder block of the engine
1.4.3.1.6 Build cylinder head of the engine
1.4.3.1.7 Build the gasket
1.4.3.1.8 Build the engine oil pump
1.4.3.1.9 Build engine heat shields
1.4.3.1.10 Build engine variable valve timing system
1.4.3.1.11 Build the spark plugs of the car
1.4.3.1.12 Build the engine ignition system
1.4.3.1.13 Build engine control module
1.4.3.1.14 Build engine bearings
1.4.3.1.15 Build starter motor
1.4.3.1.16 Build electronic spark controller
1.4.3.1.17 Build crankshaft
1.4.3.1.18 Build engine airflow sensor
1.4.3.1.19 Build crankcase
1.4.3.2 Install the engine
1.4.3.2.1 Install bearing to the crank case
1.4.3.2.2 Install first 4 pistons to the crankcase
1.4.3.2.3 Install crankshaft to the crank case
1.4.3.2.4 Link the pistons to the crankshaft
1.4.3.2.5 Install the second part of the crankcase by a robot
1.4.3.2.6 Install the remaining 4 pistons to the crank shaft
1.4.3.2.7 Crank the engine by human
1.4.3.2.8 Cylinder heads are placed in to the engine
1.4.3.2.9 Install variable valve timing system
1.4.3.2.10 Install the valves of the engine
1.4.3.2.11 Install the oil pumps and oil pan & oil filters
1.4.3.2.12 Install the ignition system
1.4.3.2.13 Install the electronic spark controller
1.4.3.2.14 Install intake manifolds
1.4.3.2.15 Install the airflow sensor
1.4.3.2.16 Install the fuel injectors
1.4.3.2.17 Install electronic throttle controller
1.4.3.2.18 Install exhaust manifolds
1.4.3.2.19 Install the engine control module
1.4.3.2.20 Install the starter motor
1.4.3.2.21 Computer assisted engine check
1.4.3.3 Deliver the engine to the main assembly line
1.4.4 Upholstery shop
1.4.4.1 Check the lather for flaws
1.4.4.2 Take the measurements using a laser beam
1.4.4.3 Cut leather by machine
1.4.4.4 Stitch the cut parts
1.4.4.5 Apply glue to stitch parts
1.4.4.6 Worker attach leather to the dash board
1.4.4.7 Make out sheets
1.4.4.8 Upholster steering wheel
1.4.4.9 Deliver Upholster items to main assembly line
1.5 Main assembly line
1.5.1 Assembly station one
1.5.1.1 Electrical wiring
1.5.1.2 Auto delivery to assembly station two
1.5.2 Assembly station two
1.5.2.1 "Install power steering lines, pedals, water lines"
1.5.2.2 Auto delivery to assembly station three
1.5.3 Assembly station three
1.5.3.1 Install fuel tank
1.5.3.2 Install dash board and Speedo meter
1.5.3.3 Auto delivery to assembly station four
1.5.4 Assembly station four
1.5.4.1 Set up transmission to the engine
1.5.4.2 "Add fuel lines, belts, wires and heat shields"
1.5.4.3 Auto delivery to assembly station five
1.5.5 Assembly station five
1.5.5.1 Attach engine to the body
1.5.5.2 Auto delivery to assembly station six
1.5.6 Assembly station six
1.5.6.1 Install two sump lubricators
1.5.6.2 Put up the exhaust system
1.5.6.3 Auto delivery to assembly station seven
1.5.7 Assembly station seven
1.5.7.1 Install the all-wheel drive system
1.5.7.2 Place the electromagnetic shock-absorbers
1.5.7.3 Auto delivery to assembly station eight
1.5.8 Assembly station eight
1.5.8.1 "Install rear bumper, tail lights, and boot"
1.5.8.2 Attach wind screen by robot
1.5.8.3 Attach the rear wind screen by robot
1.5.8.4 Auto delivery to assembly station nine
1.5.9 Assembly station nine
1.5.9.1 Attach rain sensing wipers
1.5.9.2 "Install battery, front bumper, steering wheel, and airbags"
1.5.9.3 Auto delivery to assembly station ten
1.5.10 Assembly station ten
1.5.10.1 Install key less entry system
1.5.10.2 Install the sound system
1.5.10.3 Auto delivery to assembly station eleven
1.5.11 Assembly station eleven
1.5.11.1 Install seats
1.5.11.2 Install spoiler
1.5.11.3 Auto delivery to assembly station twelve
1.5.12 Assembly station twelve
1.5.12.1 Attach the badge and name to the body
1.5.12.2 Place the tires
1.5.12.3 Auto delivery to assembly station thirteen
1.5.13 Assembly station thirteen
1.5.13.1 Finish interior
1.5.13.2 Install head lights
1.5.13.3 Auto delivery to assembly station fourteen
1.5.14 Assembly station fourteen
1.5.14.1 Put in required fluids & check the electrical system
1.5.14.2 "Check vehicle braking, speed, steering"
1.5.14.3 Deliver the finished vehicle for the check-ups
1.6 "Test prototype, alternations & review"
1.6.1 Safety
1.6.1.1 Front crash test
1.6.1.2 Rear crash test
1.6.1.3 Side impact test
1.6.1.4 Child safety test
1.6.1.5 Proper working of air bags
1.6.1.6 Proper working of seat belts
1.6.1.7 Vehicle braking distance
1.6.1.8 Electronic stability system
1.6.2 Performance
1.6.2.1 Top speed
1.6.2.2 Acceleration
1.6.2.3 Road handling
1.6.3 Drivability
1.6.4 Durability
1.6.5 Functionality of the systems
1.6.6 Mileage
1.6.7 Wind tunnel test
1.6.8 Vehicle dynamics
1.6.9 Make improvements if required
1.7 NHSTA vehicle approval
1.8 Training employees
1.9 Launch the car
1.9.1 Consider the target audience
1.9.2 Create impression about the car
1.9.3 Press releases to make customer awareness and differentiate thee product
1.9.4 Build anticipation through advertising
1.9.5 Testing on the success
1.9.6 First car launch in the most potential market (Auto show in USA)
1.9.7 Start the Production to meet the demand
(B) Vehicle Specification
Vehicle Specifications
EXTERIOR
Power glass sunroof with tilt feature and 1-touch *
control
Multi-reflector and projector headlamps *
Automatic headlamp control *
Fog lamps *
Automatic rain-sensing wipers *
Night vision rear view camera *
INTERIOR
Integrated touch screen GPS navigation *
Bluetooth®12 wireless streaming audio and hands- *
free mobile phone connection
Smart Pass keyless push-button ignition and entry *
Leather-wrapped steering wheel with cruise control *
and integrated audio controls
Information display (outside temperature, mpg, range, *
average speed)
10-way power driver’s seat adjustment with 3- *
position memory (includes power lumbar)
Rockford Fosgate®13 425-watt, 10-speaker, 8- *
channel AM/FM/CD/XM®14 audio system with
subwoofer
USB4 audio input (for MP3 or iPod®15 music *
player
SAFETY
Electronic Stability Program with FWD *
Intelligent Vehicle Stability Program (i-VSP™) with *
AWD
Bosch® Anti-lock Braking System (ABS) with *
Electronic Brake-Force Distribution (EBD)
10 air bags *
INTERIOR DIMENSIONS
Head room, front/rear (in) 39.3 / 37.0
Leg room, front/rear (in)
41.7 / 35.6
Shoulder room, front/rear (in)
55.5 / 54.6
EXTERIOR DIMENSIONS
Overall length (in) 183.1
Overall width (in)
71.7
Overall height (in)
58.3
(C)SWOT Analysis
Market Analysis
Strengths
The company is a market leader in the industry with mammoth capital in its hand. It is well
established 196 countries and people are aware of the products of the company. The well
accepted brand name is a blessing in disguise to the company as it would help a great deal to
launch the new product. The company’s well organized network and overseas bases aid a great
deal to carry out the production later even in overseas in order to tackle currency fluctuations.
The state of the art Takatsuka plant located in Japan is one of the mega factories that the world is
having. It will help the company to expand the production as it is required in a short period of
time. The Suzuki’s competitive and highly qualified employees are the driving force of the
company which makes everything possible for the company. The massive number of share
holders and the affiliations make sure the company is economically stabled and can afford to
invest in such a colossal project.
Weaknesses
The main weakness that the company has is that it doesn’t produce some of the parts in their
factories and sometimes there can be quality defects. The company has to bare some of the parts
that they purchase from other companies and has to sacrifice some profits. The limited product
portfolio in automobile industry is somewhat a problem for the company as they don’t serve the
every segments of the market.
Opportunities
The need for a super speed affordable sport sedan in the market is more that an opportunity as
the company could catch not only the larger middle class consumer base but also the upper class
individuals who values speed and the quality. The prices of the other car models in the nearest
categories like sport cars and legal street speedy cars will help to attract more customers at will
which will result in increased share value and company profits. Current there is no such car in
the in the market that can hit 0-100 Km/h in just 3.2 seconds and also generating 660HP at such a
little cost. The existing sport sedans look like little wimpy when it’s compared with the Suzuki’s
D9.
Threats
The declining automobile sales across the world are a threat to the company to reach the
expected sales due to the economic crisis. People move away from spending on a super car to
tiny cheaper cars to live up with the hard times. But with the economy beginning to recover
itself, Suzuki expects to sell more D9s across the globe. One of the biggest threats comes from
the giant rivals in the market. The brands like Porsche and Audi makes life hard for the company
to breathe peacefully even after the making of a true leader.