Process steps

Transcription

Process steps

Welcome to
TRW’s centre of
excellence for
Remanufacturing
and
HVLV
Manufacturing
1
© TRW Automotive 2012
1
Company Profile
 Headquartered in Livonia,
Michigan, US
 More than 65,000 employees
worldwide
 Balanced global presence, with
approximately 185 facilities in
26 countries, including 13 test
tracks and 22 technical centers
 Serves all major vehicle
manufacturers worldwide
 Leading developer and
supplier of active and passive
safety systems
 Ranks among the world’s
leading automotive suppliers
2
The Safety Everyone Deserves
 TRW is all about safety
– Broadest portfolio of any supplier
– 90% of TRW’s business is safety
– Committed to making technology
affordable for all
– Committed to helping to protect
people
– Committed to education about
road safety – particularly in
emerging markets
3
Product Portfolio – Safety Focus
Airbags
Driver Assist Systems
Driver & Passenger Airbags
Self Adapting Vent
Active Venting
Low Risk Deployment
Knee & Side Airbags
Curtain/Rollover Airbags
Adaptive Cruise Control
Lane Assist Systems
Collision Warning
Automatic Emergency Braking
Steering Wheel Systems
Touch Sensor in Steering Wheel Rim
Vibrating Steering Wheel
Illumination Technology
Contactless Horn System
Path-free use of Horn
Steering Wheel with Integrated Microphone
Electrical Connections
Fixed Driver Airbag Module
Body Control Systems
Efficient Climate Control
Capacitive Touch Sensors
Rain/Light Sensors
Integrated Electronic Control Panel
Seat Belt Systems
Active Control Retractor
Seat Belt Retractors
Load Limiters
Pretensioners
Active Buckle Lifter
Linkage & Suspension Systems
Electronics
Control Arms
Ball Joints
Stabilizer Links
Tie Rods
Modules
Electronic Control Units
Airbag Control Units
Crash Sensors
Video and Radar Sensors
RKE/Passive Entry
Safety Domain ECU
Pedestrian Protection
Tire Pressure Monitoring
Braking Systems
Steering Systems
Speed Proportional Hydraulic Steering
Electrically Powered Hydraulic Steering
Electrically Powered Steering Column Drive
Electrically Powered Steering Rack Drive
Anti-Lock Braking (ABS)
Traction Control
Electronic Stability Control (ESC)
Slip Control Boost
Electric Park Brake
Integrated Park Brake
Calipers
Actuation
4
Strategic Priorities
 Strategic Priorities are ingrained into TRW’s daily business
activities and are used as navigation points to guide the
allocation of resources to support research and development,
manufacturing investments and growth initiatives
Best Quality
• Drive quality in
everything we do –
products, launches,
engineering
• Ensure we make the
product right the
first time and deliver
only quality
products on time to
our customers
Global Reach
Innovative
Technology
• Position businesses
• Offer leading-edge
globally to service
key customers and
grow with new
markets
• Pursue opportunities
to diversify
customer base
systems & products
that add value for
our customers
Lowest Cost
• Relentlessly drive
down costs to offer
customers superior
value
• Leverage leadership
• Utilize manufacturing
in active and
passive safety
systems to develop
integrated product
solutions
programs (Six Sigma
and Operational
Excellence) to
manage costs to
optimal levels
5
TRW Automotive Executive Staff
John Plant
Chairman &
Chief Executive Officer
TRW Automotive
Finance
Operations
Joe Cantie
Executive
Vice President &
Chief Financial Officer
Steve Lunn
Executive
Vice President &
Chief Operating Officer
Sales & Business
Development
Peter Lake
Executive
Vice President
Legal
Human Resources
Robin Walker-Lee
Executive
Vice President,
General Counsel
& Secretary
Neil Marchuk
Executive
Vice President
6
Global Leadership in Safety – Segments
2012 Full
Year Sales of
$16.4 Billion
Chassis Systems
63%
6%
“Active Safety”
Electronics
• $10.3 billion in sales
Primary products:
• Steering systems
• Foundation brakes
• Slip control
• Actuation
• Suspension
• Chassis aftermarket
11%
20%
Occupant Safety
Systems
“Passive Safety”
Primary products:
• Safety electronics
• Driver assist systems
• Chassis electronics
• RF electronics
• Powertrain
electronics
Primary products:
• Airbags
• Seat belts
• Steering wheels
89% of sales
derived from
safety-related
products
Automotive
Components
Primary products:
• Body controls
• Engine valves
• Fasteners
7
Industry Leading Diversification
• Broad customer base and platform distribution
• Ability to leverage technology and products across customers and
regional markets
• Limits dependence on single market fluctuations and cycles
• Scale provides leverage to optimize cost structure
Industry Leading
Diversification
Product
Customer
Linkage &
Aftermarket Susp’n
2%
7%
Chassis
ABS/ESC & Other
Modules
Brake Control
16%
7%
Steering
Systems
16%
Airbags
11%
Electronics
4%
Active
Other
14%
Engine Valves
4%
Body Controls
4%
Fasteners
3%
Foundation
Brakes
15%
Passive
Steering
Wheels
4%
Seat Belts
7%
Electronics
Geographic
Volkswagen
23%
Honda 1%
Toyota 2%
Hyundai 3%
Europe
43%
Fiat 4%
BMW 4%
Ford
18%
Daimler 4%
Ren-Nis 4%
GM
10%
Auto Components
North
America
36%
PSA 3%
Chrysler
10%
Rest of World
4%
Asia-Pacific
17%
Note: Based on TRW full year 2012 sales of $16.4B
8
Supporting Customers Globally
Europe
43%
• 2012 Sales of $7.0B
• All products and aftermarket
North America
• 2012 Sales of $5.9B
Asia Pacific
17%
• 2012 Sales of $2.85B
RoW(1)
36%
• 2012 Sales of $0.7B
• Primarily Chassis and
aftermarket
4%
TRW operations cover every major vehicle producing region and are
aligned to match the future needs of our customers
(1) Primarily South America
9
TRW Automotive Global Capabilities
AMERICAS
Arizona
• Mesa
Georgia
• Flowery Branch
Illinois
• Marshall
• Melrose Park
Indiana
• Garrett
• Lafayette
Massachusetts
• Westminster
Michigan
• Brimley
• Farmington Hills
• Fenton
• Fowlerville
• Locke Township
• Livonia
• Portland
• Romeo
• Saginaw
• Sterling Heights
• Washington
• Wixom
Minnesota
• Winona
New York
• Auburn
Ohio
• Fayette
• Mogadore
• Valley View
• Warrensville Heights
EUROPE
Tennessee
• Lebanon
• Rogersville
• Sevierville
Virginia
• Atkins
Wisconsin
• Galesville
Czech Republic
Canada (Ontario)
France
• Midland
• St. Catharines
• Tillsonburg
• Windsor
• Woodstock
Mexico
• Aguascalientes
• Chihuahua
• Cienega de Flores
• El Marques
• Querétaro
• Reynosa
• Toluca
Brazil
• Diadema
• Engenheiro
• Lavras
• Limeira
• Santo André
• Taubate
• Três Coracões
• Benesov
• Dacice
• Frydlant
• Horni Pocernice-Prague
• Jablonec
• Mlada Boleslav
• Stara Boleslav
• Bouzonville
• Brest
• Dijon
• Ingwiller
• Orléans
• Paris – La Défense
• Schirmeck
Germany
• Alfdorf
• Aschaffenburg
• Aschau
• Barsinghausen
• Beckedorf
• Blumberg
• Duesseldorf
• Emmerke
• Enkenbach-Alsenborn
• Gelsenkirchen
• Koblenz
• Krefeld
• Laage
• Neuwied
• Radolfzell
• Selb
• St. Leon-Rot
• Wuescheim
Italy
Slovakia
• Bricherasio
• Cinisello Balsamo
• Gardone
• Livorno
• Moncalieri
• Nichelino
• Ostellato
• Pralormo
Sweden – Arvidsjaur
• Bytca
• Nove Mesto
Switzerland - Zug
Spain
Turkey
• Alfaro
• Barcelona
• Corella
• Madrid
• Mutliva Baja
• Olvega
• Pamplona
• Porriño
• Silla
• Valladolid
• Vigo
Poland
• Bielsko-Biała
• Czechowice-Dziedzice
• Częstochowa
• Gliwice
• Pruszków
• Cerkezkoy
• Kadikoy-Istanbul
UK
• Birmingham
• Burnley
• Cirencester
• Houghton le-spring
• Peterlee
• Pontypool
• Shirley
• Wrexham
Portugal
• Ponte de Lima
• Sao Domingos de Rana
• Vila Nova de Cerveira
Romania
• Timisoara
Tunisia
• Ben Arous
South Africa
• Atlantis
ASIA PACIFIC
India
Korea
Thailand
Singapore
• Bangalore
• Chennai
• Gurgaon
• Hyderabad
• Pune
• Bangkok
• Chonburi
• Rayong
• Ansan City
• Incheon
• Seosan City
• Seoul
• Ulsan
• Singapore City
Japan
• Hiroshima
• Miyoshi City
• Bukit Beruntung
• Tokyo
• Johor
• Toyota City
• Rawang, Selangor • Utsunomiya
• Sham Alam
• Yokohama
Malaysia
China
• Anting
• Beijing
• Changchun
• Chengdu
• Chongqing
• Heihe
• Langfang
• Nanjing
• Ningbo
• Qingdao
• Shanghai
• Suzhou
• Wuhan
• Xi’an
• Xiangcheng
Manufacturing sites, technical centers, test tracks and joint venture facilities (As of February 2013)
10
TRW Automotive Aftermarket Profile
•
Headquartered in Neuwied, Germany
•
Approximately than 1600 employees
•
Approx. 30 facilities in 23 countries
•
Serves all major original equipment
vehicle manufacturers worldwide
•
Serves all major IAM Customers
Product offering
Corner Module
Braking
Steering and
Suspension
Shocks
Remanufacturing
Diagnostic
•
80 % off all sold products are produced
in house
•
Leading supplier for remanufactured
chosen product lines
11
11
TRW Remanufactured parts
A TRW remanufactured automotive safety part is the functional and durable
equivalent of a new part and is virtually indistinguishable from a new part
12
„
Remanufacturing Definition
It is important to point out
that a remanufactured part
is different from a reused,
refurbished or repaired
part.
The CLEPA definition
of a remanufactured
product is:
A remanufactured product fulfils a
similar function to the original part.
It is manufactured using a
standardized industrial process in line
with specific technical specifications.
The industrialized process
incorporates defined core
management standards.
A remanufactured spare part is
warranted as a new spare part.
“
13
European Age of Car Parc
European Car Park Aging
1 -7 years
older 8 years
Remanufactured Safety Products in the out of warranty
market place
Second hand vehicle price and
reputation Kept higher than your
competitors
€
€
€
 Second-hand vehicles are more
sought after because of the
availability of genuine OEM
quality spares.
 Vehicles maintained using
genuine OEM parts helps
maintain price and market
presence.
 Spare parts buyers of today are
potentially the new car buyers of
tomorrow.
15
TRW Remanufactured Safety Products are Ecologically Sound
Originally Produced
Spare Part Carbon
Footprint
Remanufactured
Spare Part Carbon
Footprint
Based on our
production figures of
2012 we saved
5.000 tons of Co2.
That is equivalent to
drive 30 milion km in a
car.
257 Kg Co2
75 Kg Co2
16
TRW Automotive, Frydlant Plant
- 50,000 SqM total site
- 20,000 SqM Production and
Warehouse.
- 330+ Employees
- Sales 2012 $40M
One stop shop for:
- Disc Rotor Manufacturing
- Brake Caliper Remanufacturing and
Assembly
- Steering System Remanufacturing and
Assembly
- Distribution
17
Tier 1 supplier to:
- Vehicle Manufactures
- Intercompany
- Industry
120 km from Prague
2 km to Polish border
12 km to German border
18
Remanufactured
EPS Column Drive
Product offering development
Remanufactured
Vane Pump
Remanufactured
EPS Belt Drive
Remanufactured
EPHS MPU
Remanufactured and New
HVLV Steering Gear
Remanufactured
Caliper
New HVLV Caliper
Assembly
Remanufactured
HCV Caliper
Remanufactured
HCV Steering Box
Brake Disc
Machining
19
TRW Frydlant Operations, Management Structure
20
GENERAL PROCESS CONTROLS & DOCUMENTATION

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







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
Failure Mode and Effect Analysis (FMEA)
Control plans (PKŘ)
Process Operation Sheets (POS/SOS)
Identification sheets (ID) for all components / recovered parts
Poka-yoke on all safety critical charakteristics
100% magnetic flux crack detection on all critical parts
First off inspection per batch
Regular process and product audits
High visual management, 11colors, LEAN line design
Capability and SPC studies for key processes
Contamination measurement on each remanufacturing process
Follow of customer specifications, ISO/TS16949, VDA standarts
Regular operator training and skill matrix (ILU)
Using of 6Sigma methods (Brainstorming, Ishikawa, …)
Insert Presentation Name & Date Here
21
TRW Manufactured Safety Products
Brake Disc Rotor
22
TRW Manufactured Disc Product line
Sales by major customers 2012
Opel; 2% Volvo Car; 5%
TRW UK - Toyota; 24%
Mitsubishi; 1%
TRW Germany - IAM; 68%
23
Brake disc machining
 Customers: IAM, VMS
 Line capacity: 2100 pcs/shift
 No. produced references: 495
 Process area: 2200 m2
 Specific process steps:
– Crack detection on hub (where
required)
– Customer specific painting
– Machining of small components
– HVLV cells
24
Brake disc machining
 Process steps:
– Roughing
– Turning (super fine turning
0,8Ra, DTV and run out
measurement)
– Drilling
– 100% Balancing for ventilated
discs
– Customer specific packaging
 Material and material spec.
– Castings are made from high
quality grey cast iron (GG20,
GG15 & GG15HC spec.)
– Tensile Strength
– Hardness
– Chemical composition
25
Brake drums machining
 Customers: IAM
– HVLV cells
– S.A. according to customer
requirements
26
TRW Remanufactured Safety Products
Remanufactured / New Passenger Car Steering
27
TRW Remanufactured Steering Product line
TRW Wrexham; 0,3%
Opel; 6%
Nissan; 0,5%
TRW Germany; 50%
Ford; 15%
Honda; 0,1%
Renault; 7%
Volvo; 10%
Volkswagen; 2%
Other IAM; 0,4%
Other VMS; 0,1%
Lotus; 1%
Porsche;
0,03%
Land Rover; 7%
28
Steering gears
(overall customer portfolio)
– Crack detection on critical parts
– Testing, assembly based on
customer requirements and
specifications.
29
Steering gears
 Process steps:
– Dedicated Core manager
– Core receiving&sorting
– Core ID sheets, key know-how
within European Aftermarket
– First check and cleaning core
(tumbling, continuous washing
machine)
– Steering disassembly according
to POS
– Recovery of components
according to ID sheets
– First quality check and rejection
of recovered components
30
Steering gears
 Process steps:
– Washing of components
– Quality check of recovered
components
– All key recovered components
(housing, valve, rack bar, small
components) are
remanufactured separatelly in
dedicated cells.
– 100% magnetic flux crack
detection for all critical parts
31
Steering gears
 Process steps:
– Assembly of steering gear
– 100% yoke clearance setup
– 100% air leakage test
 Process highlights:
– High level of visual management
– Tooling sheets for all products
– Visual A.I.D. for OK/NOK parts
as highlight of critical features
– Material flow according to TRW
standart (11 colors)
– Regular quality audit, product
and process
32
Steering gears
 Process steps:
– 100% EOL test
• Mesh test
• Dynamic test
• Slip test, inner leakages
• Returnability
• Valve curve (new test rig)
– 100% torgue check on IBJ
assembly
– Final finish and bellow assembly
(black)
33
Remanufactured / New Passenger Car EPHS MPU
34
TRW Remanufactured EPAS & Pumps Product line
TRW Wrexham; 1%
Opel; 3%
Ford; 17%
Renault; 2%
TRW Germany; 68%
Fisker; 9%
35
Vane pumps
 Customers: IAM
– Water shot blasting
– Available long term testing
36
Vane pumps
 Process steps:
– Disassembly of unit to main
components (housing, cam ring,
shaft, top and bottom plate, rotor,
vanes etc.)
– Recovered components are
cleaned, sorted, checked and
stored
37
Vane pumps
 Process steps:
– Pump assembly
– 100% air leakage test
– 100% EOL functional test
• Flow test
• Pressure test
• Pressure relief valve test
– Painting
– Customer product packaging
38
EPHS pumps
 Customers: IAM, Renault, Ford,
VW, GM, Fisker
– EEPROM analysis
– brushed E-motor remanufacturing
– ECU re-flashing
39
EPHS pumps
 Process steps:
– First functional test
– Disassembly pump to main
components (tank, motor, gear set,
pressure relief valve, armature,
pump body etc.)
– Remanufacturing, cleaning and
sorting of components
– Assembly of pump
– 100% air leakage tester
– 100% functional EOL tester
• Flow
• Pressure
• Pressure relief valve function
– EEPROM analysis and check of
DTC failure codes
40
EPS Column drive
 Customers: IAM, 2013 - VMS
 Line capacity: 10-30 pcs/shift
– Diagnostic fault store
– De/soldering station
– ECU SW reflashing/reprograming
(where applicable)
– Functional EOL test machine
– Noise measurement
– TRW / non-TRW products
41
EPS - Belt Drive
 Customers: Ford - IAM, VMS
 Line capacity: TBD currently in
development
 No. produced references: TBD
currently in development
 Process area: TBD
 Specific process steps:TBD
currently in development
Launch of this product range is planned for
Q3/2013.
42
Remanufactured HCV Steering
43
Remanufactured HCV Steering Product line
DAF; 57%
Scania; 32%
Volvo Parts; 1%
TRW Germany; 7%
Daimler; 4%
44
HCV Steering box
 No. produced references:85
– Crack detectiion test
– Torque measurement at ball
station
– Poka-yoke system locking ball cap
– Pressure decay test
– Functional EOL test with valve
curve measurement
45
TRW Remanufactured HCV Steering facility
 Process steps:
– Disassembly of unit to main
components (box housing, sector
shaft, worm shaft, piston, covers,
small components etc.)
– Recovered components are kept
and match together on trolley
– Ultrasonic cleaning machine used
for washing of one unit set
– Remanufacturing of all
components and checked for
quality
– 100% crack detection on all critical
components
46
 Process steps:
– Specialized tools and operations
are designed for all products
– Ball station with implemented
Poka-yoke systems is used for
assembly piston S.A.
– Automated measurement of travel,
number of balls in S.A., securing of
ball bridge
– Automated check by camera
– All results are stored in PC for
back traceability
47
 Process steps:
– 100% control on all high torque
connection
– 100% air leakage test on final
assembly to check sealing of unit
– 100% EOL functional test
• Friction test
• Valve curve
• High pressure test
• Internal leakage – slip
• Limiter valve test
• Reversability
– Engraving of serial number linked
with test results
– Painting
– Customer packaging
48
TRW Manufactured Safety Products
New Passenger Car Braking
49
Remanufactured Braking System
50
TRW Manufactured and Remanufactured Caliper Product line
Ford; 7%
TRW Germany - HCV
Proequip; 0,1%
Volvo; 2%
LandRover; 0,2%
Volkswagen; 1%
TRW Wrexham; 24%
Industry; 12%
TRW Germany - New; 20%
TRW Germany Remanufactured; 31%
GM; 1%
51
Brake calipers
 Customers: IAM, Continental,
Teves, Ford, Volkswagen, GM
Group, Land Rover, Volvo, Brake
Engineering, Black Module
– 2 lines available
 Process area: cca 800 m2
– Assembly as well HVLV production
of new calipers.
52
Brake calipers
 Process steps:
– Disassembly of calipers to
recovered components
(housing, levers, springs, small
components etc.)
– Shot blasting
– Zinc plating
– Cleaning of housing and small
components after dismantling
and zinc plating
53
Brake calipers
 Process steps:
– Small parts recovery and
remanufacturing
– Assembly of calipers
– 100% EOL test
• Low pressure
• High pressure
• Roll back
• Hand break lever movement
– Engraving date code
– Filling station (where required)
54
HCV calipers
 Customers: IAM
– Setup of actuator
– Measurement of wear test sensor
55
Remanufacturing Process - Caliper
2.
3. + 4. Cores
cleaning
process
Break Down
1. Cores
receiving,
sorting &
stocking
5. Zinc
plating
6. + 7. Assembly
& testing
8. Marking
8a. Rear caliper :
Filling with break
fluid
9. Packaging
8b. Front caliper :
56
TRW Remanufacturing/Manufacturing Product Launch
All remanufacturing/Manufacturing process parameters
are derived from OEM drawings and specifications
Vehicle
Manufacturer
TRW
57
 APQP activities cover Design and Process FMEA reviews,
lessons learnt in OE are implemented into Remanufacturing
process
 New materials used are from TRW approved suppliers
58
TRW Aftermarket, Remanufacture:
59
Remanufacturing Product Launch
Our Customer Product Engineering is
supported by TRW’s global Engineering
resources including:
• TRW Tech, Shanghai China
• TRW Engineering, JB, Malaysia
• TRW Tech, Düsseldorf, Germany
• TRW Koblenz, Germany
• TRW Pamplona, Spain
• TRW Jablonec, Czech Republic
• TRW Italia, Gardone, Italy
• TRW RPD, Rogersville, USA
• TRW Dacice, Czech Republic
Off-tool samples can be durability tested in
TRW Test and Validation Laboratories
60


Our Customer Product Engineering is supported by TRW’s global
Engineering resources including:
– TRW Tech, Dusseldorf, Germany
– TRW Koblenz, Germany
– TRW Pamplona, Spain
– TRW Jablonec, Czech Republic
– TRW Italia, Gardone, Italy
– TRW RPD, Rogersville, USA
– TRW Dacice, Czech Republic
Off-tool samples can be durability tested in TRW Test and Validation
Laboratories
61




Deflection test
High speed-braking test
Fatigue life-cycle test
Salt spray test
Field testing capabilities
 Track test (Koblenz)
 Alpine test
62
TRW Frydlant Plant Major Accreditations
 TS16949 : 2009
– Successful Audit September 2012
 ISO14001: 2004
– Successful Audit November 2012
 General Motors
– “A” rating
 Volkswagen Group
– VDA 6.3 95% “A” rating
 Daimler
– VDA 6.3 91% „A“ rating
 Renault
– Process audit rating 91%
 Fiat
– Process audit rating 93%
 Ford
– Q1 status
63
Summary
Remanufacturing is supporting ecological goals and
is within TRW a part of our core business strategy.
Professional remanufacturing will be as well the
solution for a long term supply chain
TRW is leading the way in
remanufacturing
 Awarded remanufacturer of the year
award 2010
64
Thank you for your
attention
WE PUT THE THINKING IN
REMANUFACTURED
SAFETY SYSTEMS.
Integrated Remanufacturing thinking. Our
Cognitive Safety Systems are elevating the
intelligence of safety Remanufacturing.
Seamlessly Remanufactured technology
that analyzes and adapts to ever-changing
conditions to help keep passengers and
drivers safer. Always aware. And always
thinking.
65
65

Process steps

Transcription

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