The First Fit for Quality Academy Schaeffler Worldwide

Target: Zero Defect

INA Skalica, INA Kysuce Fit for Quality Project

Fit for Quality Academy

30. 6. 2014 INA Kysuce, a.s. Page 1

Kysucké Nové Mesto

Region Žilina Number of inhabitants 15,680 Industry Mechanical engineering

Kalvária

Skalica

Region Trnava Number of inhabitants 15,013 Industry Mechanical engineering and paper industry

INA Skalica est.1991 4620 employees

INA Kysuce est.1999 4017 employees

http://de.wikipedia.org/wiki/Skalica

30. 6. 2014 INA SKALICA spol. s r.o.

INA Skalica building phases Total production area: 77,400 m2

G01

G02

G03

G04 G06

1997 12,000 m2

G01 1999 12,000 m2

G02 2007 27,000 m2

G06 2004 6,400 m2

G04 2002 20,000 m2

G03

2a

2000 19 108 m2 1 2003

22 849 m2 2 2006 3 574 m2 4 2005

35 484 m2 3 2007 4 133 m2 5

1

2

3 4

5

30. 6. 2014 Page 3

2012 4 614 m2 2a

INA Kysuce, spol. s r.o.

INA Kysuce building phases Total production area: 92,053 m2

Wheel bearing unit with sensor

Taper roller bearing Tandem angular

contact ball bearings

Bucket tappet Camshaft adjuster

Finger follower with hydraulic pivot element

Needle roller bearing

Overrunning alternator pulley

Chain tension system

Strut bearing

Switching unit

Lightweight balancer shaft with rolling bearing supports

Toothed chain timing drive

Ball screw Torque converter

Clutch release system

Dual-mass flywheel

SAC

Double clutch systems dry/wet

Clutch linings

Transmission components

Alle

Rec

hte

vorb

ehal

ten

für L

uK, i

nsbe

sond

ere

für d

en F

all e

iner

Sch

utzr

ech

Engine and transmission components

Components for clutch and transmission systems

Wheel modules and transmission bearings

Wheel bearing with face spline

Deep groove ball bearing

Products made in ILS and IWK

30. 6. 2014 INA SKALICA spol. s r.o. Page 6

Production program Segment 02 (B) Product line 10 Needle bearings Products IR, LR, KI F-, flanged rings Main customers GETRAG GETRIEBE VW, SEAT, ŠKODA ZF, FORD, SKF, DAIMLER

Segment manager Ľudovít Musil

30. 6. 2014 Page 6

Industrial


Production program Segment 04 (D) Product line 03 Compensating elements Product line 10 Needle bearings Product line 13 Track rollers, support rollers Products NK, NKI, RNA, NA, RNAO, NAO, NKS, NKIS, NKIA, NKIB, NX, NKX, NKXR, RSTO, STO, RLB, GLB F-, IR, AGWL Main customers VW, GEARBOX, ŠKODA, BMW, SCANIA, ZF, DAIMLER, AUDI, BOSCH, KARL MAYER

Segment manager Peter Stašek

30. 6. 2014 Page 8

Industrial


Production program Segment 05 (E) Product line 26 Axial needle bearings Products RG, SS, WS, GS, LS, ZS, TWA, TWD, VRS, AR, SSL Main customers INA-COMPANIES, ZF, VW, HYUNDAI, GM, DAIMLER, VOLVO, SCANIA, AGCO

Segment manager František Trojek

30. 6. 2014 Page 9

Automotive


Production program Segment 07 (G) Product line 04 Linear bearings Product line 08 Tensioning rollers Products RSH, RSEH, RSEMD,RSEMZ, RSEMB, RSEMC, RSEMZK, KB, KN, KS Main customers HONDA, TOYOTA, VW, SEAT, ŠKODA, AUDI, RENAULT, VOLVO, PSA, BMW, GM, PORSCHE, DAIMLER

Segment manager Peter Pekárek

30. 6. 2014 Page 10

Automotive


Production program Segment 08 (H) Product line 09 Welded cages, cut out cages Products KZK, K, RNA, NK Main customers ZF, DAIMLER, HYUNDAI, VW, GETRAG, SCANIA, VOLVO, STIHL

Segment manager Petr Buček

30. 6. 2014 Page 11

Industrial


Production program Segment 09 (I) Product line 25 Gear shift units Product line 27 Synchronizer rings for gearboxes Products Gear shift units, clamping fixtures, seat height adjusters, KLV, SYRZ, SYRI Main customers VW, GETRAG, GM – OPEL, DAIMLER, FIAT, AUDI, ZF LS

Segment manager Mário Vach

30. 6. 2014 Page 12

Automotive


Production program Segment 10 (J)

Product line 12

Cylindrical rolling

bearing supports

Products

RN, RNN, HUTR, NUTR, KI,

RNU, NUP, NU, NJ, ZL,

SL01, SL04, SL18, SL19

Main customers

BOSCH, LIEBHERR,

JOHN DEER, STILL,

JUNGHEINRICH, JCB,

VOLVO, VW , ZF, GFT

Segment manager Roman Kudláč

30. 6. 2014 Page 13

Industrial


Production program Segment 13 (M)

Product line 27

Synchronization

Products

SYRZ, SYRI

Main customers

GETRAG-FORD

PSA, VW, RENAULT, FIAT

Segment manager Martin Látal

30. 6. 2014 Page 14

Automotive


Production program Segment 14 (N)

Product line 43

Release bearings

Products

ARL

Main customers

LuK, GETRAG, VW, FORD,

FTE, HONDA, FIAT, BMW

Segment manager Marián Vach

30. 6. 2014 Page 15

Automotive


Production program Segment 15 (O)

Product line 28

Industrial applications

Products

Sensor bottom bracket bearing

BBRTS

Main customers

BOSCH

30. 6. 2014 Page 16

Industrial Segment manager Mário Vach


Production program Segment 16 (P)

Product line 11

Needle bearings

Product line 21

Universal joint bearings

Products

HK1, BK, BU

WLT: RK, H, B, DKA

Main customers

BOSCH, CONTINENTAL,

BMW, HELLA,

THYSSEN KRUPP,

VALEO, WILLY ELBE, ZF LS,

IFA ROTORION –

POWERTRAIN GmbH

Segment manager Pavol Majkut

30. 6. 2014 Page 17

Industrial

30. 6. 2014 Strana 20

Production range MU1 - Segment 02 Product line 14 Ball bearings and radial insert ball bearings Products Radial insert ball bearings and housed bearing units Main customers John Deere, Class, CNH, Krones AG, VanDerLande, Brammer, Haluk, Werthenbach

Manager of Segment Martin Tuchyňa


30. 6. 2014 Page 21

Production range MU2 - Segment 03

Manager of Segment Ľuboslav Ďurica

Product line 14 Ball bearings and radial insert ball bearings Products 61800, 61900, 3800, 3900 Main customers LUK, Mercedes, SKF


30. 6. 2014 Page 22


Manager of Segment Martin Ormis

Product line 08 Idler pulley units Products Radial ball bearings with injection-moulded plastic belt pulley or metal belt pulley pressed-on, or other pressed-on clamping elements according to customer's requirements Main customers VW, PSA, Renault, AUDI, Daimler, GM, Ford, Volvo


30. 6. 2014 Page 24


Manager of Segment Slavomír Fecman

Product line 12 Cylindrical roller bearings Products HULR, KTRK, HMTR, LRQ (Lift mast rollers) Main customers Jungheinrich, Linde, Still


30. 6. 2014 Page 25


Manager of Segment Peter Čižmárik

Product line 33 Wheel bearings Products Wheel bearings of 3rd generation Main customers BMW, ZF, VW, AUDI, Daimler, Ford


30. 6. 2014 Page 27


Manager of Segment Daniel Pecko

Product line 33 Wheel bearings Products Components for (OR, FL) for wheel bearings of 2nd and 3rd generations Main customers BMW, ZF, VW, AUDI, Volvo, Ford, GM / Opel, Daimler


30. 6. 2014 Page 28


Manager of Segment Miloš Mizera

Forge Products Forgings for components for wheel bearings of 1st, 2nd and 3rd generations


30. 6. 2014 Page 30


Manager of Project František Bakoš

Product line 14 Ball bearings and radial insert ball bearings Products Tandem-Angular contact ball bearings Main customers BMW, ZF, Magna, Daimler


30. 6. 2014 Page 31


Manager of Segment Gabriel Michalec

Product line 55 KGT – Ball nut assembly Products Parking brake Ball nut assembly Main customers Audi, TKPS, TRW, Volvo


30. 6. 2014 INA SKALICA spol. s r.o.

TOP customers of INA SKALICA and INA Kysuce

14.5.2014


https://www.google.sk/url?q=http://logo-s-collection.blogspot.com/2009/11/harley-devidson-logo-wallaper.html&sa=U&ei=evV-U4D6K6XyyAOY6YHABQ&ved=0CC0Q9QEwAA&usg=AFQjCNFeuvdYbKpoWWSZmth3mf2Bt1gRcw

Best in Class


https://www.google.sk/url?q=http://www.qatarmark.com/companies/information/hilti-qatar.html&sa=U&ei=0_R-U5PQLKPzygP4_oD4BA&ved=0CEUQ9QEwDA&usg=AFQjCNEBTliQpGduDgvf_XdgUvQv_KhS6Q

35

Next Projects KGT Lenkung RCEPS Porsche Volumen 120.000/Year Mando GMI700 – SUV Volumen 250.000/Year Hyundai TRW Volumen 280.000/Year

Tesla Model S – new design SOP Q2/2014 Volumen 160.000/Year

Tesla Model X – new design SOP Q1/2015 Volumen 250.000/Year

Mando GMxx – new design SOP Q2/2014 Volumen 320.000/Year


Page 36

Replacement of tapered roller bearings by angular contact ball bearings

Comparison of bearing friction torque

0,00

0,50

1,00

1,50

2,00

2,50

2 3 4 5 6 7 8 9 10

axial load [kN]

fric

tio

n t

orq

ue

[N

m]

TBB FAG F-239495TRB low frictionTRB standard

Standard Tapered roller bearing

Low friction Tapered roller bearing

Tandem ball bearing FAG F-239495

SWOT analysis for each FfQ Axiom

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SWOT analysis for each FfQ Axiom

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A hundred point FfQ action plan

Massnahmen Fit for Quality

Time-schedule for establishing FFQ Academy

One hundred-point FfQ action plan

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100 %

1. Quarter 2. Quarter 3. Quarter 4. Quarter January February March April May June July August September October November December

1. Team nomination

2. Team training

3. Determine the training concept

4. Determine the training content

5. Technical equipment

100%

100 %

100 %

100 %

100% Training room

Training equipment 100 %

100 %

100 %

6. Test of training (Feedback and optimalization)

7. Training schedule

8. Run the trainings

Fit for Quality Academy Roll-out in IWK 2012

14.5.2014

Costs: 20.000€ 14x Working tables, 2x Poka-Yoke, 2x Press, Parts for two assembly lines, 2x Scales,...

The costs were released from Mr.Patka and Mr.Suess in April 2012.

First visualisation – Assembly room

14.5.2014

14.5.2014

Daily: 18 participants and 2 trainers 8 teoretical blocks 10 practical excercises 2 assembly simulations

Duration: 8:00 – 16:00, 8 hours

First visualisation – Training room

A short video from Schaeffler TV:

14.5.2014

http://intra1.schaeffler.com/download/hzapub/uk/mitarbeitermedien/schaeffler_tv/en/schaeffler tv special fit for quality-academy_en.html

Number of trained employees: 2012 (2.10.2012 – 31.12.2012) – 382 persons 2013 (1.1.2013 – 31.12.2013) – 2816 persons* 2014 (1.1.2014 – 30.4.2014) – 1408 persons *(including participants from China, Hungary and Romania)

Fit for Quality Academy training

Fit for Quality Academy in INA Kysuce plant

14.5.2014

Fit for Quality Academy in INA Kysuce plant

14.5.2014

Who can not affect the quality of the product in our company ? Axiom 1 – Quality is everyone's responsibility

Development

Construction

Logistic

Material

Production

Control

Packing and storing

Sale Service

Marketing

The importance of SWOT analysis and the possibilities of its use

Axiom 2 – SWOT in every workplace

Development

Construction

Logistic

Material

Production

Control

Packing and storing

Sale

Service

Marketing

TO PREVENT SENDING A WRONG PARTS TO A CUSTOMER!

What is the purpose of a Near Miss analysis program?

How the program was born? - Near Miss program comes from facilities of Schaeffler North America

- The main objective was to reduce the number of customer´s complaints

- As result : reduction of claims in 2009 by 22%

Axiom 3 – Near Miss Analysis

The importance of layered audit Axiom 4 – Layered audit

Examples of some findings from audits: Bad / weak ergonomy of a workplace Overloaded boxes in a production Lost or wandered parts

Permanent education is an expensive investment for a company. This investment is necessary because only well trained employees are capable to perform high quality work continuously.

Try to think how the range of products produced by our company has changed over the past few years. Are we producing more simple or more complex products over the years?

Why is high qualification of employees important in our company?

Axiom 5 – Permanent training, high qualification of employees

Axiom 6 goal: - To understand the life-cycle and the importance of a Quality in it.

PEP = Produkt Entstehnung Prozess – The process of a product creation.

RLA = Risk Level Assesment – The assessment of a project risk level.

FMEA = Failure Mode Effect Analysis – Analysis of possible failure and the consequences.

Axiom 6 – Thorough Use of Existing tools

F-580224.02 YD: 180.000 in 2015

http://www.bmwcoop.com/wp-content/images/2012/03/BMW-i8-Concept.jpg

Daily, about 80,000 commercial airplanes take off all over the world. How many of them would crash on daily basis if their processes would be assured on:

95 % - 99 % -

99,99 % -

4000 daily 800 daily 8 daily

100% processes are therefore essential to achieve our "zero defect" goal

Why exactly 100% processes?

Axiom 7 – 100% process ensuring, 100% sure processes

Example from our simulation

Axiom 8 – Lessons learned

Name: Jig for screw tightening Area: Assembly Centre: Fit for Quality Academy

Axiom 8 – Examples

Before After

Tightening the screw was not ergonomic and not precise.

Installation of special jig, for tightening the screws on the working table.

The tightening is now ergonomic and precise.

Problem Solution Result

Number of the example: 0076 Author: Assembly Realization: KW48

Fit for Quality Academies Worlwide

Schaeffler Romania Schaeffler India Schaeffler China

14.5.2014

Roll-out Plan in Schaeffler World

14.5.2014

Fit for Quality Academy Schaeffler Romania, Brasov

14.5.2014

Fit for Quality Academy Schaeffler India, Pune

14.5.2014

Fit for Quality Academy Schaeffler China, Taicang

14.5.2014

Thank you for your attention!

The First Fit for Quality Academy Schaeffler Worldwide

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