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Project 04: Toyota Yaris Roof Moulding Production set-up Project title Production set-up of exterior trim parts Company Decoma, a division of MAGNA Location Belgium, Eigenbrakel (Waterloo) Client Toyota Yaris Location France, Valenciennes. Timing, duration Sept. 1997 to Dec. 1998 Brief description of the project Toyota decided to build a new factory in Valenciennes in France to make the Yaris. MAGNA got the contract to supply the roof mouldings. The roof mouldings are basicaly made by co-extrusion of 2 different kinds of plastics. They also contain a U-shaped core material in cold rolled stainless steel. Finishing of the products imply endcap injection moulding and marking. As a Project Manager, I had the full P&L responsiblility for the overall project. My activities included: all coordination between Toyota and the manufacturing plant, planning and budget control, design review, business development, tier1 supplier audit and selection, manage the equipment and tool design and purchase, material tests and selection, various QA activities. Training of the operators, foremen, QA and logistics staff. Application of ISO 9001, TS16949, CAD/CAE, TPS, JIT, Jidoka, FMEA, DOE, RASIC, Best Practice. Application of the Japanese approach of Project Management: absolute respect for planning, good communication, teamwork, fair supplier and subcontractor management. Management of the prototype and R&D dept in Heiligenhaus, Germany.. Reporting to the General (plant) Manager and the Business Development Manager