Mazda 2016 Annual Report Download - page 24

Monotsukuri Innovation
CHECK Integrated Planning / Common Architecture
– Design intent faithfully reproduces in mass-production vehicles
– Development and application of designer colors Soul Red and Machine Gray contribute to enhancing brand value
Efforts to realize high levels of diversity, which enhances
the competitive edge of our products, and commonality,
which boosts the efficiency of mass production
Looking five to 10 years into the future, we have implemented Monotsu-
kuri Innovation for efficiently developing and manufacturing products,
making possible common development methods and manufacturing
processes by using integrated planning for models to be introduced in the
future, spanning market segments and model classes.
Optimized structures of each function are shared across all car lines
and laterally spread to each car line based on the integrated planning.
A flexible production system is used to produce products engineered
based on a common architecture concept in a highly efficient and flexible
way. We are aiming to raise operational efficiency through building a
flexible production process that can handle changes in volumes and can
quickly introduce new models with a minimum of investment.
Monotsukuri Innovation enabled Mazda to make more competitive products while
improving costs
CHECK New Design Color: Machine Gray
Under the idea that color is one of the elements of form, Mazda has been focusing its efforts
on developing colors, such as Soul Red, and coating technologies that accentuate the subtle
yet dynamic surfacing of KODO design. The new design color Machine Gray, which is slated to
be used for new model CX-9 and MX-5 RF, was developed to express the beauty of a machine’s
strength and precision. With strong contrast between light and shadow and a sleek, high-densi-
ty finish, Machine Gray gives the impression that the vehicle’s body has been sculpted from a
solid steel ingot. As a color that complements the KODO design, Machine Gray is contributing
to improvements in brand value.
Performance Improve Cost / Efficiency
R&D efficiency 30% or more
Investment in
production
facilities
SKYACTIV-G/D 70% or more
Vehicle 20% or more
Cost
improvement
Vehicle
(excluding additional equipment)
100kg or more weight reduction
(equivalent to 5% fuel economy improvement)
20% or more ¬ 30% (target)
SKYACTIV-D 20% better fuel economy, Euro6 compliance Better than previous engine
SKYACTIV-G 15% better fuel economy and torque, possible to comply
with Euro6
Better than previous direct
injection engine
SKYACTIV-DRIVE 4%–7% better fuel economy, direct feeling improvement Same as previous transmission
AFTER: Total Optimization
Engine series
Transmissions
Body series
Chassis series
Other components
One R&D / production concept for
all car lines
Pursue scale merits for entire lineup
Integrated Planning: Looking at trends 5 to 10 years ahead
SUV
C/D
C
B
BEFORE: Separate Optimization
C
B
C/D
SUV
ProductionR&D
ProductionR&D
ProductionR&D
ProductionR&D
Optimized structures of each function are shared across all car lines
and laterally spread to each car line.
SUV
C/D
C
B
Through Monotsukuri Innovation, our new products since the CX-5 and SKYACTIV TECHNOLOGY have achieved
improved efficiency in terms of both product development and manufacturing facility investment as well as significant
improvements in vehicle costs.
Monotsukuri Innovation has yielded significant results at our domestic production
sites (our “mother plants”), and going forward we will expand this to include over-
seas production sites and our supply chain to achieve high-quality, highly efficient,
and flexible production and improve the cost structure on a global basis. We also
intend to increase flexibility in our production of sedans and SUVs to maximize
production capacity at our major production sites.
As we pursue these initiatives, global human resource development will play a
major role. Our aim is to create an environment and structure in which employees
who understand and share the Mazda vision are able to stand out and play a role at
overseas production sites.
Global deployment of Monotsukuri Innovation
Mexico Plant
MX-5 RF
MAZDA ANNUAL REPORT 2016
22 Drivers of Value Creation
Message from
Management
Review of Operations
Foundations Underpinning
Sustainable Growth
Financial Section
Contents