World Manufacturing Forum - 10/16/2012
How to build up a Learning Manufacturing
Organization in a Global Environment
Werner Müller, Executive Vice-President Diesel Systems
Diesel Systems
1
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
2
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
3
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Three business sectors - 2011 key figures
Bosch Group


Automotive
Technology

Industrial
Technology

Consumer Goods
and Building
Technology

1



51.5 billion euros in sales
302,500 associates
including 38,500 in research and development
59% share of sales
Leading supplier of cutting-edge automotive
technology
16% share of sales
World's leading manufacturer of large gearboxes,
drive and control, packaging, and process
technology
25% share of sales1
World's largest power tool manufacturer, leading the
field in household appliances, heating and cooling,
and security systems
Including other segments
Diesel Systems
4
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Diesel Systems - 2010/11 key figures
2010
2011
Sales to Third Parties [bn EUR]
~7.5
~8.0
sales outside Germany [%]
>80
>80
Associates []
associates outside Germany [%]
Capital Expenditure [m EUR]
R&D Expenditure [%]
~50.000
~50.000
~70
~70
>200
>400
~11
~11
Diesel Systems
5
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Arguments pro Diesel
Clean Diesel
–25%
–30%
+50%
 30% less fuel consumption
 25% less CO2 emission
 50% higher torque
... than comparable gasoline engines
Diesel Systems
6
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
DS-Product-Portfolio and Application (selection of main DS-products)
Common Rail System 2 – passenger car
Common Rail
System 3 – commercial vehicle
Common Rail System 3 – passenger car
Common Rail System – Large Engines
Rail
Glow Plug
Unit Pump System
Sensors
Denoxtronic Exhaust-gas treatment
Diesel Systems
7
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
8
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Worldwide Customer Base
 Our customers require a perfect quality of 0 ppm and 100% delivery
fulfillment all over the world independent from our production locations
Diesel Systems
9
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
International Footprint of Diesel Systems
Bamberg Budweis
Jihlava
Homburg
Wien
Feuerbach
Linz
Venissieux
Hallein
Rodez
Offanengo
Saratov
Farmington Hills
Bari
Kentwood
Charleston
Bursa
Jaipur
Nashik
Bangalore
Ansong
Daejon
Wuxi
Amata City
Curitiba
Production location
Development location
 24 Production locations in 14 countries
 Worldwide approximately 50.000 associates at Diesel Systems
Diesel Systems
10
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distribution, as well as in the event of applications for industrial property rights.
Ota City
Yorii
World Manufacturing Forum - 10/16/2012
Worldwide Supplier Network of Diesel Systems
Number of suppliers for Diesel Systems 2011
Europe
Asia & Pacific
Americas
Purchasing volume for Diesel Systems 2011
Europe
Asia & Pacific
Americas
 Our worldwide 1.600 suppliers with a purchasing volume of more than
2 bn EUR per year have to be integrated in our global production network
Diesel Systems
11
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World Manufacturing Forum - 10/16/2012
Product Variance and Volume of Diesel Systems
Example Product Generations (Passenger Car CR-Injector)
Production Volume (selection of DS-products)
N° of part numbers (selection of DS-products)
4.201
CR-Pump (passenger car)
692
CR-Pump (commercial vehicle)
402
285
67
CR-Injector (passenger car)
CR-Injector (commercial vehicle)
Nozzle
 Continuously increasing volumes, generations and product
variance causes permanent ramp-ups all over the world
Diesel Systems
12
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Functionality of Common Rail System
Valve
High degree of flexibility for
shaping the injection-rate.
Up to 8 single injections per stroke
performed in a narrow time slot.
Pump
Control
Unit
Rail

System Pressure

2000 bar
“comparable
with the
weight of a
big car (2 tons)
pushing on
a finger nail”

Minimal duration of one injection

0,12 milliseconds
“one blink of an
eye lasts about
100 milliseconds
and is therefore
comparable with
50 to 100 injections”
Diesel Systems
13
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
Quantity of one injection

5 mm³/stroke
“comparable
with approx.
one twentieth
of the volume
from a water
drop”
World Manufacturing Forum - 10/16/2012
Technical Requirements: Common Rail Injector
- Laser welding
Magnet group
- Assembly/testing
Armature lift setting 1µm
- Grinding
Tolerances <1 µm
- Deburring
edge radius <10µm
- Diamond-like-carbon-coating
- High sensitivity on particles
- Eroding & HE rounding
- Matching needle and body
clearance <1 µm
 Producing at the edge of technology means to ensure
worldwide the corresponding technical competences
Diesel Systems
14
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
15
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Lead Plants and International Production Network
One lead plant per product family:


Develop manufacturing
processes
Define standards for
worldwide usage
Plan and coordinate the
production worldwide
Homburg (HoP)
CRIN, Rail, CPN5, RP
Bamberg (BaP)
CRI, Nozzle
Feuerbach (FeP)
CP, UI
Hallein (HlP)
ZP, LE, DNOX
Rodez (RzP)
GLP
Offanengo (VHIT)
Vacuum pump
Charleston (ChP)
UIN

Japan (DS-JP)
CPN2
Jaipur (JaP)
VE
Curitiba (CtP)
UP
 12 Lead plants for the international production network
Nashik (NaP)
NH
Bangalore (BanP)
PF-Pump, A-Pump
 24 Production plants organized in 20 International Production Networks (IPN)
 Worldwide standards for production and quality
* updated: 01.2012
Diesel Systems
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World Manufacturing Forum - 10/16/2012
Success Factor: IPN Cooperation
Success
Success Factors
Factors
Focus
Focus on
on all
all levels
levels to
to achieve
achieve
common
goals
common goals
Production
Plant 1
Continuous
Continuous information
information
exchange
exchange
Lead plant
The German Lead Plants
are the role models for the
production plants in the IPN
Mutual
Mutual acceptance
acceptance of
of
competences
competences
Consequent
Consequent use
use of
of existing
existing
structures
structures
Production
Plant 2
Employee
Employee exchange
exchange including
including
management
management
Close
Close cooperation
cooperation
Production
Plant ...
 The IPN cooperation is the basis of a successful Learning
Manufacturing Organization in a global environment
Diesel Systems
17
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World Manufacturing Forum - 10/16/2012
The Importance of Continuous Qualification
“The future of our industry,
and any progress in the
technical field, depends on the
training of capable mechanics
and technicians.”
(from: Bosch-Zünder, 4 (1922))
Robert Bosch
† March 12, 1942 Stuttgart
Diesel Systems
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
General education and Bosch trainings
Technical
School
Shop Floor
Specific
apprentice-
Training
Qualifi-
ship
Excellence
cation
system
School
University
Program
identified
Job
Rotation
and
Bosch
Manage-
associate ment
by ComJunior
LeaderExchange Service
petence
Managers
Ship
and
Manage- Program
Graduate Development
Specialist
ment
Program
General education
Bosch trainings
Retirement
Age
 Bosch drives the continuous learning organization over the entire worklife
Diesel Systems
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World Manufacturing Forum - 10/16/2012
International Apprenticeship in Diesel Systems
Examples of technical apprentice programs for each region
Program: Industrial Mechanics
Industrial Electronics
Duration: 3,0 years
Program: Set-up Mechanic
Maintenance Mecha.
Duration: 2,0 years
In plant or
training center
In plant or
training center
School
(outside Bosch)
78%
65%
22%
School
(outside Bosch)
35%
Bursa
Charleston
Wuxi
Program: Technican (Maintenance, Mechanic, etc.)
Duration: 3,0 years
Bangalore
Program: Industrial Mechanics
Duration: 2,5 years
In plant or
training center
60%
School
(outside Bosch)
40%
Curitiba
Program: Mechanic
Electrican/Electronics
Technican (Maintenance Mechanic, etc.)
Duration: 3,0 years
In plant or
School
training center (outside Bosch)
100%
In plant or
training center
School
(outside Bosch)
55%
0%
 We built up apprenticeship programs together with the
respective state authorities (duration of apprenticeship 2-3 years)
Diesel Systems
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45%
World Manufacturing Forum - 10/16/2012
Apprenticeship Programs “made in Germany”
Extracts of article in Wall Street Journal from 06/2012
 German education stands for successfully
combining theory with practical experience
Diesel Systems
21
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World Manufacturing Forum - 10/16/2012
Associate Exchange Program (3 – 5 years)

DS-Expatriates in and outside
of Germany on all levels

Distribution of German
expatriates in the regions [2012]
500
400
300
200
EU
AM
100
AP
0
2008
2009
2010
German Expatriates going abroad
2011
2012
Expatriates from abroad in Germany
Expatriates from abroad outside Germany
 The associate exchange program is an integrative part of a our leadership
development and our Learning Manufacturing Organization
Diesel Systems
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Integrated Qualification Concept for the
Bosch Production
System at Diesel Systems
Training
starts with
management to
ensure
leadership
support
5 Executives
40 Plant Managers
680 Department Heads
1,150 Supervisors
2,600 Team Leaders
30,500 Operators
Ongoing
coaching
and
training
including
implementation
on
shopfloor
 Worldwide rollout of the standardized target group specific trainings
within the last 5 years as a common basis for continuous improvement
Diesel Systems
23
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
24
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Organization IPN & Strong Leadership

Example: Common Rail Injector passenger car (CRI)
CRI IPN
Bamberg
Homburg
10 Plants
Rodez
Bursa
Nashik
Daejon
Higashimatsuyama
Wuxi
Amata City
Curitiba
Leadplant
Plant
Diesel Systems
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distribution, as well as in the event of applications for industrial property rights.
IPN
World Manufacturing Forum - 10/16/2012
Cooperation between Leadplant & Production Plants
International Production Network CRI
Production plants:
Production lines:
Production lines:
Part numbers:
5
~115
Leadplant Bamberg (DE)
10
35
Capacity:
Part numbers:
Production lines:
1
Part numbers:
~16
Production lines:
1
Part numbers:
~12
Production lines:
3
Part numbers:
Production ~120
lines:
2
Part numbers:
~58
Production lines:
3
Part Production
numbers: lines:
~34
2
Curitiba (BR)
PartProduction
numbers: lines:
~40 13
Amata City (TH)
Part numbers:
~325
Production lines:
2
Wuxi (CN)
Part numbers:
~12
Production lines:
5
Daejon (KR)
Part numbers:
~47
Nashik (IN)
Higashimatsuyama (JP)
Bursa (TR)
Rodez (FR)
Homburg (DE)
Diesel Systems
26
~175.000 pcs/day
~700
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World Manufacturing Forum - 10/16/2012
How do we find the right direction?
Right direction!
 Only by determining the actual place can you find the right direction
Diesel Systems
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World Manufacturing Forum - 10/16/2012
Topics within Leadplant Responsibility

Fast ramp-up of new lines (Lean-Line-Design, Standardization, etc.)

Manufacturing concepts and reuse of machines worldwide

Optimized MAE utilization and OEE-tracking

Coordination of customer releases

Systematic process and quality improvement

Early interdisciplinary process development

Coordination projects with purchasing and development

Tracking of fix and variable costs / Benchmarking
Leadplant Responsibility
Investment
Allocation
of Volumes
Knowledge
Management
Cost
Reduction
Diesel Systems
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World Manufacturing Forum - 10/16/2012
Associate Involvement at Ramp-up Planning
Line layout by manufacturing engineer

Mock-up line


Simulation of logistic, assemblyprocess and setup
Detailing of concept with focus
on employee transactions

Check of ergonomics

Confirmation of layout

Possibility for training
 By mock-up lines lessons learned of the operators
can be used directly in planning new machinery
Diesel Systems
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World Manufacturing Forum - 10/16/2012
Industrial Engineering at Diesel Systems

Examples of worldwide standards in Industrial Engineering
Basis: german and international laws as well as Bosch norms

Time data management





Methods and tools for time data calculation

MTM (Methods-Time Measurement) for batch,
small batch, mass and single piece production
Line balancing
Multi machines using
…..
Work design and work organization






Ergonomics
Work methods
Continuous Check
Standardization
Software “Man-model”
…..
Diesel Systems
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distribution, as well as in the event of applications for industrial property rights.
www.mtm-international.org/
www.mtm.org
www.dmtm.com
www.ukmtm.co.uk
World Manufacturing Forum - 10/16/2012
Optimized Machine Utilization and OEE-tracking
Value
Wertstrom
stream
Abtaktungsdiagramm
Line balance
Shopfloor
Shopfloor
Management
Management
Cycle
Hourly tracking
PDCA-Chart
Stundenaufschrieb
Cycle
Problem
solving sheet
Problemlösungsblatt
OEE with losses
OEE-Verfolgung
Pareto
of losses
Paretoanalyse
 The Shop Floor Management Cycle is a standardized procedure for the
quick and sustainable improvement on the shop floor in every plant
Diesel Systems
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World Manufacturing Forum - 10/16/2012
System-CIP
 Systematic derivation and implementation of improvement activities
 Project priorities and leverage validated along KPI trees based on value contribution
 Covers the entire value stream including Source, Make and Deliver
Reduce CT
VS-Map
Increase OEE
Increase yield
Decouple
customer fluctuation
• Regular process: frequency < 6months
VS-Design
 Stabilized and improved Value Stream performance (e.g. output, productivity)
Diesel Systems
32
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
EFQM = European Foundation Quality Management
MBNQA = Malcom Baldrige National Quality Award
EFQM at Diesel Systems


Diesel Business Excellence at DS is based on the EFQM-Model and essential for all DS-sites.
EFQM is internationally recognized and comparable with the quality management model MBNQA.
Enablers

The EFQM-Model provided by the
European Foundation of Quality Management


Results
Leadership
Leadership
a holistic management model and
basement of a common language and mindest
a tool for assessments to identify strengths
and improvement potential
People
People
Processes,
Processes,
Products &
&
Products
Services
Services
People
People
Results
Results
Strategy
Strategy
Key
Key
Results
Results
Customer
Customer
Results
Results
Partnership
Partnership
Society
Society
Results
Results
&
&
Ressourcen
Ressourcen
Learning, Creativity and Innovation
Business Unit
Commercial Vehicles
Diesel Systems
R4E 4* / EFQM
Global Assessment
R4E 5* / EFQM
Global Assessment
National Excellence Awards in several plants / countries: India, Brazil, Germany, France, Turkey, Austria, Czech Republic
2008
2009
2010
2011
Bursa
Rodez
Bamberg
EFQM
Excellence
Award Winner
EFQM Excellence
Award Finalist
and Prize Winner
EFQM Excellence
Award Finalist and
2x Prize Winner
2012
Bari
Bamberg
EFQM Excellence EFQM Excellence
Award Finalist and Award Winner and
2x Prize Winner
Prize Winner
Recognized for Excellence Assessment remarks for International Production Network:


Lead Plant/IPN-concept is a good model for leveraging and managing the global manufacturing network
This enables a strong learning and sharing experience across different regions
Diesel Systems
33
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
1
Bosch Group and Diesel Systems
2
General Conditions of Manufacturing in Diesel Systems
3
Building up a Competence Network
4
Example of a Learning Manufacturing Organization
5
Outlook and Summary
Diesel Systems
34
DS/EM | 10/16/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Success Factors for Diesel Systems and the
Learning Manufacturing Organization

Management by supporting and fostering




continuous improvement process driven by leaders on all levels
involvement of all associates
worldwide standardized and trained methods and tools
The Learning Manufacturing Organization of Diesel Systems is based on


technical competence as fundament
different possibilities for education, training and learning
 apprenticeship system
e.g. foreman (German: Meister), set-up mechanic, mechatronic, electrician

engineer qualification
e.g. mechanical or electrical engineering, industrial engineering

Global exchange program on all levels and mandatory for all future leaders
Diesel Systems
35
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Key Messages

Lead with content! Be a role model for continuous learning and
improvement in order to change the mindset for a learning
organization on all associate levels!

Focus on technical expertise as base of your own learning
manufacturing organization!

Strengthen your Production System with an holistic approach
and transparent project deployment!

Implement the success story of the apprenticeship system on a
global base!
Diesel Systems
36
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distribution, as well as in the event of applications for industrial property rights.
World Manufacturing Forum - 10/16/2012
Matthias Claudius: Brief an Sohn Johannes 1799
Matthias Claudius
1740 - 1815
Worte sind nur Worte
und wo sie gar leicht und behende dahin fahren,
da sei auf der Hut,
denn die Pferde, die den Wagen mit Gütern hintern sich haben,
gehen langsameren Schrittes.
Diesel Systems
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World Manufacturing Forum - 10/16/2012
Thank you for your attention.
Diesel Systems
38
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distribution, as well as in the event of applications for industrial property rights.