Automotive News - February 25, 2008 - (Page 10)

10 • FEBRUARY 25, 2008 Former NUMMI exec applies Toyota ideas to aircraft industry Mark Rechtin mrechtin@crain.com SAN FRANCISCO — A former Toyota executive is using lessons learned at NUMMI, Toyota’s lean laboratory in Fremont, Calif., to change the way small aircraft are built. David Coleal is putting in place lean manufacturing techniques at Cirrus Design, an up-and-coming producer of planes with built-in parachutes. As a result, Cirrus is assembling its planes faster and with higher quality. “We’re bringing automotive manufacturing lessons to general aviation,” Coleal says. Of course, while building a car may not be easy, it doesn’t have to fly, he says. A quality control glitch with a single-engine prop plane would have disastrous consequences. At New United Motor Manufacturing Inc., the Toyota-General Motors joint venture plant in Fremont, Coleal was a quality control engineering manager, immersed in the Toyota Production System. After six years with Toyota during the 1990s, Coleal left to help the startup of a Caterpillar assembly plant. From there, he joined the McKinsey & Co. consulting firm in 2001. automotive manufacturing lessons to general aviation. “ We’re bringing DAVID COLEAL Cirrus Design ” Coleal quickly installed the Toyota Production System on the Duluth, Minn., assembly line. The lean manufacturing techniques helped Cirrus shave the build time from 44 days to 21. That means a new aircraft is rolling off the line every 2.5 hours. Along with company founders and brothers Alan and Dale Klapmeier, Coleal has helped make Cirrus a rising star in the general aviation world. pilot becomes ill and the other occupants don’t know how to fly. Cirrus would prefer it not come to that, so planes have high-tech avionics gear. Video displays scroll among map, radar, weather and terrain settings. Gauges for virtual altitude, attitude, heading and speed have duplicate old-style “steam gauges” below. Twin Garmin GPS units give another layer of redundancy. An auto-pilot setting reduces fatigue. Cirrus planes are built from a composite structure rather than aluminum, for more flex during turbulence. A split airfoil on the wings aids stability. There is an ice protection system for the wings, though the planes are not certified by the Federal Aviation Administration for icing conditions. “ At one point, I found myself in the same job sitting behind the same desk, working with the same group of people and having three different employers within one year and 12 days. WILLIAM KOZYRA Continental Auto Systems North America ” Kozyra’s resume reflects volatile supplier climate In an era of consolidation, you can change jobs without changing desks illiam Kozyra knows something about career changes in the volatile North American auto industry. He has worked for six auto parts makers but made only one career change on his own. The CEO of Continental Automotive Systems North America, a unit of Germany’s Continental AG, is a veteran of the industry’s consolidation. “At one point, I found myself in the same job sitting behind the same desk, working with the same group of people and having three different employers within one year and 12 days,” he recalls. That experience, he says, has helped him better explain to employees of the former Siemens VDO Automotive the challenges they face after the company’s takeover by Continental. Name: William Kozyra Title: CEO of Continental Automotive Systems North America Age: 50 Lives: Oakland Township, Mich. Works: Auburn Hills, Mich. Education: Bachelor’s degree in mechanical engineering, University of Detroit; M.B.A., Michigan State University Family: Married to Ulrike, with three children Big break: In 1994, when the Budd Co. named him president of its brake and chassis unit at age 37 How did you get your start in the auto industry? My father had his own business, Modelcraft Industries Inc., making wood patterns, die models and prototypes. I was 9 years old and Kaizen in Minnesota Coleal has instituted Toyota’s kaizen process into product development, meaning Cirrus is far from sitting on its laurels. The lineup receives a minor change every six months, a major change every 12 months and a redesign every 18 months. More than that, Cirrus is working on developing a single-engine private jet, which Coleal hopes will be ready in 2010 or 2011. Not only does kaizen keep the technology fresh, it gives Cirrus owners a reason to come back and buy the latest offering. Says Coleal: “Cirrus has accounted for the incremental growth in the industry and all the innovation.” c Built-in parachute All Cirrus planes — which cost from $214,900 to $542,900 — have a built-in parachute in case the plane or pilot runs into trouble. A red handle in the cockpit deploys the parachute, floating the whole contraption to terra firma. The seat belts contain optional airbags. The seats are made from aluminum honeycomb, to help absorb impact. Cirrus has nearly 4,000 planes in the air. Only 12 parachutes have been deployed to date, usually when the W Person to person sweeping the mill room, making 25 cents an hour. Why did you decide not to take over the family business? There was a realization in the late 1970s that this was a dying craft. It would go away as more computers were used. What would you change about your life? I would not change anything. Look at my experience: five wonderful experiences, one career move, and global experience and understanding. Are you into sports? I like the outdoors, fishing, hiking and skiing downhill. I like sports cars and like to be around cars and like to go to car shows. What do you drive? I have a 2000 Corvette convertible and a BMW Z8 Roadster — two of my favorites. I drive an Escalade; I’m a big-car kind of guy. What do you do to relax? We travel. A couple of years ago we rented a home on one of the outlying islands south of Venice, Italy. We stayed in a 1,000-year-old home. We had a motor boat so we could provision ourselves. — Robert Sherefkin Found Cirrus through client One of his first assignments was Cirrus, on behalf of a client looking to invest a chunk of capital in the company. After doing due diligence for two months, Coleal was offered an executive post at Cirrus. He accepted the job and soon was promoted to COO. obituaries Bill Brewbaker Jr. MONTGOMERY, Ala. — Bill Brewbaker Jr., chairman of the board of Brewbaker Motors Inc. here, died here Jan. 21 at age 73. He became CEO of the family dealership, which sells Chrysler, Jeep, Dodge, Infiniti and Kia vehicles, in 1986. John Brockway LIVINGSTON, Mont. — John Brockway, former owner of Bill Ussery Motors Inc., of Coral Gables, Fla., died here Nov. 11 at age 70. Ussery Motors, one of the seven original U.S. Mercedes-Benz dealerships in 1957, was founded by Bill Ussery, Brockway’s father-in-law. Brockway sold the dealership to his son, Bob, and his wife in 2006. http://www.mudd.com http://www.mudd.com http://www.yourchevyagency.com

Table of Contents Feed for the Digital Edition of Automotive News - February 25, 2008

Automotive News - February 25, 2008 Chamco's 'consultant' is forced into limelight Group 1, Gulf States clash Dealer profit stuck in neutral Ghosn: Autos are in recession NHTSA investigates Toyota, Pontiac cars' windows The upside of upside down: Better belts Push buttons will alter interiors Schwarzenbauer leaves Porsche for Audi CSM: Cuts in auto output to ease in 2nd quarter Ford's Hispanic ad campaign takes it to the mat Hydrogen slips as a solution for the greening of autos Kia to spend big to upgrade dealerships GMAC: Office cuts won't affect dealers LaSorda: Chrysler's $700 million axle plant is 'going up' Toyota hybrid battery partner boosts output Buick may add a car below the LaCrosse Toyota could add 2 more small vehicles to U.S. lineup Calif. regulators shoot for 40-plus mpg by 2020 Loyalty/conquest: Power's best, worst Chrysler firm on retrieving tools from Plastech Former NUMMI exec applies Toyota ideas to aircraft industry Kozyra's resume reflects volatile supplier climate Obituaries Chrysler, Plastech now have chance to work together Do it the NADA way Hail, Geneva; spring must be near Volt's potential is unlimited The Volt is terrific; give GM a hand Beware of high tech running amok Teach reporters half full/half empty Dealer wants to view Conti exec: Inside, it's about the info Dealers Caddy chief's goals: Build on CTS, prestige, high-tech Geneva looks like another green scene Volvo XC60 system senses impact, hits the brakes Saab 9-1 concept awaits green light GM: Supply of vehicles to certify will stay steady Used-vehicle supplies up, prices down in Jan. Black Book plans daily updates Cars.com rolls out video service Manheim launches search tool Luxury sales channel is high on GM agenda GM seeks dealers' help with 5-point green plan Northwood offers dealer MBA Court rejects Chicago dealer's appeal Taxes distort Jan. sales in Europe Nissan to cut designers NHTSA studies window woes Bank: Autos easier to afford VW labor boss gets jail term Delphi sells 2 units Toyota Tundra had tough Jan. Chrysler's white knight: We're investors, not heroes Ford's 'Knight Rider' is Sync on steroids GMAC parties have lost a bit of their pizazz Global warming? It's a crock - but . . . Nardelli's NASCAR debut is a winner A frosty reception for the TSX

Automotive News - February 25, 2008

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