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Project 05: Toyota Corolla Roof Moulding Production set-up Project title Production set-up of various exterior trim parts for Toyota Corolla Company Decoma, an operating division of MAGNA Location Belgium, Eigenbrakel (Waterloo) Client Toyota Corolla Location United Kingdom, Burnaston (Birmingham) Timing, duration Oct 1995 to Sept. 1998 Brief description of the project Toyota decided to make their new European Corolla in Burnaston. Magna-Decoma got the contract to supply the exterior trim parts: roof mouldings and window finishing strips. These parts are made by co-extrusion of 3 different kinds of plastics. These products also contain a core material in either cold rolled stainless steel or glassfibre wire. Finishing of the products imply stretchbending, 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