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Project 06: Toyota Avensis Various trim parts Production set-up Project title Production set-up of various exterior trim parts for Toyota Avensis Company YMOS-Happich, later Decoma, and MAGNA Location Belgium, Eigenbrakel (Waterloo) Client Toyota Europe Location United Kingdom, Burnaston (Birmingham) Timing, duration Feb. 1994 to Sept. 1997 Brief description of the project Toyota made its first cars in Europe in Burnaston, UK in 1992 YMOS-Happich got the contract to supply the exterior trim parts: doorbelts, roof mouldings, window finishing strips. All these parts are basicaly made by co-extrusion of 2 or 3 different kinds of plastics. Al products also contain a core material in either cold rolled stainless steel or glassfibre wire. Finishing of the products imply flocking, stretchbending, metal cutting and bending, 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