North America
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10North America May/June Zoom Safety is a team effort June may be National Safety Month, but Faurecia focuses on keeping employees safe in the workplace everyday. There are many rules to follow and tools available through the Faurecia Excellence System to make safety second nature. The Group is in the midst of a worldwide effort to further improve and standardize safety and safety rules at each site. As Faurecia Chairman and CEO Yann Delabrière believes, safety is a mindset which must take root in each employee. Inside this issue you’ll find that the safety mindset is taking root and spreading at our sites. Find out what employees say keeps them safe everyday. Also, find answers to your questions about why Personal Protective Equipment (PPE) is one of the most important safety tools around. Continued on page 4 2 New global R&D center in Bavans 3 Gladstone celebrates success of partnership 7 Chevrolet Cruze: challenging preconceived notions 2 Group News New global R&D center in Bavans Modernized and expanded, the Bavans center is to become the global R&D center for Faurecia Emissions Control Technologies N ow No. 1 in the world for emissions control technologies with the acquisition of EMCON Technologies, today Faurecia has the means to broaden its R&D capacity with the introduction of its new global center located in Bavans, France. The inauguration ceremony, led by Yann Delabrière, Chairman and CEO of Faurecia, took place in the presence of several local and regional elected officials and representatives. After the ribbon cutting, guests were able to visit the site where 26 programs related to new vehicles and around 20 innovation programs are already currently in development. The new center is designed to develop tomorrow’s emissions control technologies and contribute to the design of a new generation of cleaner cars. Its four main pillars of innovation are environmental remediation solutions for gasoline and diesel engines, improving engine efficiency, recovering energy and acoustic solution design. The products involved include the complete exhaust system; specifically the manifold, catalytic convertor, diesel particulate filter, exhaust heat recovery system and muffler. Faurecia Automotive Exteriors: No. 1 in Europe W ith the acquisition of Plastal’s activities in Germany, FAE becomes No. 1 in Europe for exterior automotive components. With its four product lines (frontend modules, front-end carriers, bumpers and engine cooling systems) and with a market share of 22 percent, FAE eclipses its main competitors: Plastic Omnium, Magna and Peguform. Beyond the European market, FAE aims to pursue its main development in China and the United States, spurred on by high demand from its main German clients. FAE now has 4,500 employees working in 21 factories and four R&D centers in six countries. Product sales for Q1 up by 41 percent F aurecia’s sales for the first quarter of 2010 have soared to 3.2 billion euros, 533 million of which are from EMCON. This represents an increase of 59.5 percent compared with the same period in 2009. For a fixed area and exchange rate, quarterly growth Asia + 92% North America + 68% is 32.2 percent. Product sales (deliveries of components and parts to manufacturers, excluding monoliths, equipment and development for third parties) have increased by 40.7 percent. South America + 40% Europe + 31% 3 Site Life Alabama welcomes Faurecia to Cottondale Leroy named CFO for North America On March 29, Faurecia appointed Vincent Leroy as new Chief Financial Officer for North America. He will promote the use of Shared Services accounting platforms and will have responsibility for all tax and banking relations. He will work closely with the Divisions’ controllers and IT organization to improve finance processes and internal controls. Leroy remains the North American Division Controller for FIS and is based in Auburn Hills, Mich. ‘Company of the Year’ award presented by FACC O n April 8, Faurecia hosted a celebration of its Cottondale, Ala. Plant (FAS), to thank state and local governments and community organizations, as well as other partners, for their support of the project. Construction of the new FAS just-in-time plant began in February and will be completed early this fall. The facility will supply complete seats for Mercedes-Benz vehicles produced in nearby Vance, Ala., starting next year. At full production, the Cottondale plant will have nearly 200 employees and will produce more than 500 seats per day. More than 60 people attended the event, including Alabama Gov. Bob Riley, who presented Faurecia with the State Seal. Gladstone celebrates success of partnership with Cummins On April 12, employees from the Gladstone Plant in Columbus, Ind. (FECT) and Cummins Emission Solutions gathered to celebrate the success of the EPA 2010 diesel particulate filter (DPF) program. About 100 people attended the lunch. The partnership was formed in January 2009, with limited production of the DPF starting up in October. Full production was accomplished on January 4, 2010. As of April, more than 7,000 DPFs have been shipped with no quality complaints from customers and without exceeding cost. “The proof of the partnership is evident in the extraordinary results delivered by the CES/Faurecia team in starting full production just 11 months after the announcement,” said Dan Davis, Cummins General Manager of Advanced Emissions Business. Cummins reported that the technology leadership of Cummins Emission Solutions combined with the world-class manufacturing capability of Faurecia Emissions Control Technologies enable the alliance to deliver competitive marketleading after-treatment systems to meet increasingly stringent emissions regulations globally. The French-American Chamber of Commerce, Michigan Chapter (FACC) named Faurecia its “Company of the Year” for its role in the advancement of French-American business relations. The award was presented during the FACC’s annual gala on April 30 in Bloomfield Hills, Mich. The gala celebrated the Belle Epoque, an Era of Progress and Optimism, and benefited Doctors Without Borders. Each year, the Michigan Chapter names one France-based and one America-based business, “Company of the Year.” Faurecia, headquartered in Nanterre, France, won the award for its significant contribution to French-U.S. trade and commerce. BorgWarner Inc. was honored for its role in creating a more diverse business community. “It is an honor to be recognized for our commitment to French-American relations, which are so important to international business,” said Mike Heneka, President of Faurecia North America. “The active involvement and leadership roles that Faurecia commits to the FACC are reflective of the importance we feel the organization has in helping to continuously improve relations between French and American businesses.” As a non-profit, non-political organization, the FACC is dedicated to the development of commercial relations between French and American businesses. Welcome Faurecia Tuscaloosa On April 30, Faurecia Interior Systems acquired a new facility in Tuscaloosa, Ala. The plant, formerly owned by Visteon and then Nissan, produces various interior components including instrument panels. The 105,000 sq. ft. facility employs 88 people and allows Faurecia to expand its customer base and footprint in the southeast United States. Vehicles supplied from Tuscaloosa include the Nissan Armada, Frontier, Pathfinder, Titan and Xterra. faurecia faureciainfos infosNA NA••May/Jun Mar/Apr 2010 2010 4 Zoom Safety is no accident Protect yourself by using PPE everyday Continued from page 1 PPE is designed to protect employees from serious workplace injuries or illnesses resulting from contact with chemical, physical, electrical, mechanical or other hazards. Besides face shields, safety glasses, hard hats and safety shoes, PPE includes a variety of devices and pieces to wear, such as goggles, coveralls, gloves, vests, earplugs and respirators. Each Faurecia site has rules about what PPE is required for employees and visitors to the site. If you don’t know what the guidelines are, ask your site HSE coordinator. Here are a few frequently asked questions about why PPE is important, from the U.S. Occupational Safety and Health Administration (OSHA). For more information, go online to www.osha.gov. Or go to www.canoshweb.org for the Canadian Centre for Occupational Health and Safety. site It’s important for every employee in each onal Pers ing wear for s eline to follow the guid vest, Protective Equipment (PPE) like a safety glasses and gloves. “In addition to PPE, Taking responsibility for my own safety. Recognizing the hazards associated with my tasks and those around me. Implementing safe working procedures and encouraging safety by following all safety rules and procedures to help me prevent near misses and injuries. – Nikkia Warner, Troy Plant Watch what you’re doing; if there’s water on the floor mop it up dry; make sure you bend your legs; don’t over lift totes that are too heavy. – Katha Collins, Franklin Plant Jeremy Flory reminds us to pay attention during safety chats or during Top 5s when safety is addressed. Other associates and myself following safety rules, core team audits and management providing us with safe equipment to work with keeps us safe on the job everyday. – Pat Childress, Fountain Inn, S.C. On the cover: When it comes to our sites, safety is no accident. Some of the important ways our employees recommend to stay safe are to follow standardized work rules; keep areas clear of debris; be aware of your surroundings; and follow the proper way to operate machines. Performing my daily safety checks to ensure all of my safety devices are working properly. – Sherman King, Louisville, Ky. Plant Knowledge of equipment and knowing the proper way of performing my job duties (standardized work). – April Broughton, Louisville Plant Safety first, always have an open mind. Think before your act. Watch out for yourself and others. Always review your weekly Top 5 safety topic. – Tammy Lewis, Troy, Ohio Plant Knowing your surroundings, being aware of who and what is working around you at all times of the day. The best safety precautions are thinking and paying attention. – Josh Hawes, Toledo, Ohio JIT Plant The reminders of our safety chats, the constant visual displays of potential hazards. – Jeremy Flory, Franklin, Ohio Plant Staying aware of my surroundings, common sense and Lockout/Tagout. – Micah Adamson, Franklin Plant Sherman King says safety checks to ensu re all safety devices are working properly are important. s, Many employee e ar say being aw staying safe. 5 Can PPE protect employees from head injuries? Yes. Hard hats can protect against head impact, penetration injuries and electrical injuries such as those caused by falling or flying objects, fixed objects or contact with electrical conductors. Also, OSHA regulations require employers to ensure that employees cover and protect long hair to prevent it from getting caught in machine parts such as belts and chains. How can PPE protect workers from foot and leg injuries? In addition to foot guards and safety shoes, leggings (e.g., leather, aluminized rayon or other appropriate material) can help prevent injuries by protecting employees from hazards such as falling or rolling objects, sharp objects, wet and slippery surfaces, molten metals, hot surfaces and electrical hazards. What can PPE do to protect workers from hearing loss? Wearing earplugs or earmuffs can help prevent damage to hearing. Exposure to high noise levels can cause irreversible hearing loss or impairment as well as physical and psychological stress. Earplugs made from foam, waxed cotton or fiberglass wool are self-forming and usually fit well. Clean earplugs regularly and replace those you cannot clean. Does PPE help protect workers from eye and face injuries? Should workers wear PPE to help prevent hand injuries? Yes. Besides spectacles and goggles, PPE such as special helmets or shields, spectacles with side shields, and face shields can protect employees from the hazards of flying fragments, large chips, hot sparks, optical radiation, splashes from molten metals, as well as objects, particles, sand, dirt, mists, dusts and glare. Yes. Workers exposed to harmful substances through skin absorption, severe cuts or lacerations, severe abrasions, chemical burns, thermal burns and harmful temperature extremes will benefit from hand protection. what keeps you safe on the job everyday?” In Bradford, we believe in teamwork and “Everyone’s safety is everyone’s responsibility.” To achieve this, there are three foundations for safety: • Discipline: as a worker, I know my responsibilities and I make sure that I am fit to work at all time so I can focus and be alert to everything I do. • Respect: I respect and comply with all the safety rules and regulations of this plant. I do not engage into any unsafe activities that will affect my wellness and the safety of my co-workers. • Awareness: I’m always aware of all the risk that may occur around my surroundings, such as tow motors, pedestrian walkways and following standardized work. - Laura Yourkin, Bradford, Ontario Plant Keeping debris picked up from aisle ways. Always be aware of your surroundings because they are always changing. Keep focused on the job that you are doing at the present time. – Justin Vorhees, Troy Plant Vorhees, , including Justin ngs is key to di un rro su of your ve In Bradford, respect is a one way to achie y safet plant with g plyin com ding inclu safety, rules and regulations. Above all, my own awareness of parts/surrounding environment is what I trust most. Light curtains, which prevent cycle starts while I’m in a machine. Automatic arc shields, preventing flash. Maintenance practices. Good Lockout/Tagout procedures. – James Bishop, Franklin Plant The attention of the forklift drivers watching for pedestrians, especially at the intersections. Also, the daily safety reminders that we go over and sign off keeps all safety concerns in the forefront of your mind. – Bob Jones, Franklin Plant Forklifts are a m oving hazard in most sites. Bob Jones remin ds us to be awar e of forklifts, and drivers shou ld be aware of pe destrians. Be aware of your surroundings. Make sure there are no trip hazards. Do not operate any machine unless you have been properly trained. – Ivan Tischendorf, Louisville Plant faurecia infos NA • May/Jun 2010 6 In Short Franklin, Hermosillo Improvement Ideas named FECT best O n March 30, Faurecia Emissions Control Technologies North America presented awards to two of its best implemented Improvement Ideas at its semi-annual All-Employee Meeting. Nominations were received from each of the FECT sites in the region at the end of 2009. Each site submitted an II that it felt contributed most to the improvement of the site’s Quality, Cost, Delivery and Safety performance. During this meeting, they also presented a special award for the best Quality II. All of the nominees were reviewed by the FECT North American Division senior management team. “If you truly believe in FES, you believe that improvements come from the people who do the work,” said Mark Stidham, President of FECT in North America. “For many of these nominees, it isn’t about the cost savings. The success story is about the culture of improvement we’re creating.” Award winners were chosen from each category at the AllEmployee Meetings. The winners were: Best Quality Idea Larry Gauze, Franklin, Ohio Gauze created a stand with a device that provides a visual and audio signal for the operator. This device detects and signals an incorrect or incomplete weld. The investment for this change was $1,000. Before the installation of this device, there were three customer concerns filed with the plant. Afterwards, zero concerns were reported, improving customer satisfaction. Best Overall Idea Ricardo Leyva, Hermosillo, Mexico Leyva revised the e-glass filling process to allow for more threads of fiber to be filled into each bag without affecting texturing and quality. E-glass is a packing material used in a muffler to insulate noise. This new process, which required an investment of $10,000, reduced overtime by 64 hours per week, saw $70,000 of equipment cost avoidance, freed 200 square feet of floor space and is expected to save $250,000 per year in total costs. Fiat announces its five-year plan, future of the Chrysler Group Fiat is spinning off its industrial holdings from its automotive operations, in a bold move that relies heavily on its partnership with Chrysler Group to succeed. “Today, Fiat enters a new chapter in its history and takes on a new shape,” Sergio Marchionne, CEO of Chrysler Group and Fiat said. “The time is now right to proceed with a spinoff.” Chrysler is along for the ride. Marchionne stressed that the key synergies of savings, shared product development, purchasing, manufacturing and sales were crucial to the success of Fiat auto. Together, Fiat Auto and Chrysler revenues could reach $139 billion by 2014. Fiat will consist of automotive units: the Fiat, Lancia and Alfa Romeo volume brands, luxury Ferrari and Maserati, powertrain and components divisions. A new company, to be called Fiat Industrial, will include the commercial and truck division and the agricultural and construction equipment division. Marine and industrial powertrain work will stay within this group. Economies of scale will be realized as Fiat and Chrysler develop families of vehicles in three segments: minicars, small cars and compacts. Each segment will generate more than one million vehicle sales for Fiat and Chrysler by 2014, said Harald Wester, head of Fiat engineering and design. “Of 51 new products for Fiat in the next five years, one-third will come from Chrysler,” Marchionne said. Many will be made in Chrysler plants. He avoided specifics but said Alfa Romeo will become a full premium brand and could source a sedan from Chrysler's Brampton, Ontario plant. Alfa's return to the U.S. has been pushed back to 2012 and while some Alfas could be sold in Maserati dealers, Marchionne expects Chrysler dealers to be the main distribution network. The combining of the Chrysler and Lancia brands in Europe will produce eight new products in the next five years – six of them based on Chrysler models. A plan to better utilize Fiat's plants in Italy calls for them to produce one million vehicles annually by 2014 – 300,000 of them for export to North America. “Sharing development cost with Chrysler is crucial,” Wester said. In return, Chrysler taps into Fiat's ability to develop a new vehicle in as little as 15 months. Together they save $803 million in engineering costs by 2014. Synergies with Chrysler are expected to amount to $2 billion in savings by 2014. Source: The Detroit News Photo contest deadline is July 31 Heading out on summer vacation? Take infos along with you for fun, snap a photo and you could appear in the newsletter or on the 2011 Faurecia calendar. The “Where in the world has infos been?” photo contest is going on now through July 31. When you submit a photo you are entered to win a prize. Submit high-resolution digital files or printed photos for consideration. Please include your name, site name, contact information and details about the location of the photo. E-mail [email protected] or mail them to: infos Photo Contest, c/o Communications, 2500 Executive Hills Blvd, Auburn Hills, MI 48326. 7 Industry News 2011 Chevrolet Cruze: challenging ‘preconceived notions’ about small cars T he 2011 Chevrolet Cruze is the first in a family of all-new Chevrolet small and compact cars designed to offer excellent fuel economy, outstanding quality and top safety ratings. It offers the spaciousness and amenities of a midsize car, combined with segment-leading features and details that challenge preconceived notions about what a compact car should be in North America. Leveraging Chevrolet’s design and engineering talent in Asia, Europe and North America, the Cruze brings a progressive, globally influenced design complemented by exceptional levels of quietness, quality and attention to detail – from precise tolerances between body panels to the use of premium materials throughout the interior. Chevrolet engineers have already logged more than four million miles in quality and durability testing worldwide, making the Cruze one of the most real-world-tested products prior to U.S. launch. Faurecia will supply the catalytic converter for the exhaust system from the Port Elizabeth, South Africa Plant (FECT), and the tracks for power seats from the San Luis Potosi, Mexico Plant (FAS). The Cruze will be in showrooms in the fourth quarter. Daimler, Nissan and Renault join in small-car alliance In April, Renault-Nissan and Daimler unveiled a strategic partnership to share small-car technology and powertrains. The move comes as automakers are rapidly joining forces to cut costs. The companies agreed to jointly develop the next generation of Daimler’s smart cars and Renault’s Twingo. The Renault-Nissan alliance will provide diesel and gas engines for smart. Daimler will provide engines for Infiniti, and Renault and Nissan will provide diesel engines and transmissions for the Mercedes-Benz Vito van. The companies also said they would work together on electric cars, an area in which Renault and Nissan have been investing heavily. The companies stressed that they had no intention of pursuing a full merger. Daimler and the Renault-Nissan alliance agreed to exchange equity stakes, such that Nissan and Renault will each hold 1.55 percent of Daimler’s shares and the German company will hold 3.1 percent in each of its new partners. Source: The New York Times Ward’s Auto names best interiors dimensions • • • • • Length: 181 inches Width: 74.4 inches Height: 67.9 inches Wheelbase: 106.3 inches Cargo Volume: 34.2 cubic feet • • Engines • • 1.8-liter, DOHC I-4 engine that delivers 138 hp and 125 lb.-ft. of torque • 1.4-liter, turbocharged, DOHC I-4 engine that delivers 138 hp and 148 lb.-ft. of torque • Available in LS, LT, LTZ, RS and ECO models • EXTERIOR • Design features a two-tier grille with the iconic Bowtie logo; an arching roofline that connects a steeply raked windshield and fast-sloping rear pillars to give the car a sporty, coupe-like proportion • Wider and longer than most of its competitors; it has taut, tightly drawn bodywork that conveys solidity, while restrained use of exterior trim enhances the high-quality feel • 16", 17" and 18" tires available INTERIOR • All models share an interior characterized by upscale materials and a lengthy roster of equipment usually found in larger and more expensive vehicles The hallmark twin-cockpit motif is matched with high-quality materials and exceptional assembly tolerances Grained, soft-touch components and lowgloss trim panels, which are uncommon in the segment A stereo system that includes MP3 playback capability, six speakers and an auxiliary jack for personal playback devices is standard Available technologies include Bluetooth and a navigation system SAFETY • 10 standard air bags including frontal, head curtain side, front and outboard rear-seat sideimpact and new knee air bags • StabiliTrak electronic stability control with rollover sensing, traction control and anti-lock brakes • Collapsible pedal system, which allows the pedals to detach during a crash to reduce the risk of leg or ankle injuries • Three-point seatbelts and adjustable head restraints • Tire pressure monitoring system is standard • OnStar • Strong, unitized body structure that incorporates high-strength steel in key areas to enhance strength and crash protection Ward’s Auto announced its honorees for excellence in automotive interiors for 2010. The awards were handed out in a ceremony on May 19. Among the winners was the Chevrolet Equinox in the popularpriced truck under $39,999 category, and the Chevrolet Camaro in the sports car segment. The Volvo XC60 received the award for premium-priced truck and the BMW 5-Series Gran Turismo was presented with the Design Versatility award. All four vehicles feature Faurecia content. In total, 10 awards were presented. The Auto Interior of the Year awards judge vehicles on aesthetics and design harmony, comfort, driver information, ergonomics, fit and finish, materials, safety and overall value. BMW reaches milestone in S.C. Since its arrival in South Carolina in 1992, BMW has exported more than one million vehicles from its Spartanburg assembly plant, the automaker announced in April. More than 70 percent of the vehicles produced at the site are exported to more than 120 markets worldwide. “Our plant continues to be a sustainable resource within the BMW Group,” said Josef Kerscher, President of BMW Manufacturing. “The vehicles we produce are driven around the globe and we recognize the vital partnerships we have that enable us to reach our customers everywhere they are.” The site is the global producer of the BMW X5 and X6, and began production of BMW’s first fullhybrid vehicle, the ActiveHybrid X6. It will expand to build the next-generation X3 at the facility. Faurecia supplies the complete seats, instrument panel, center console, door panels and cold-end of the exhaust system for the X5 and X6. faurecia infos NA • May/Jun 2010 8 Spotlight Creative license FIS employees recognized for patented inspiration T he life-blood of most companies is innovation. Offering customers technology they’ve never seen before or that helps set them apart from a crowd can mean more business. Innovation, as we know, can be a simple change in thought or it can be a ground-breaking new approach. Overall, it is a pathway for continuous improvement. Each year, Faurecia invests money back into the company to develop innovations. The outside world recognizes these innovations officially through patents. A patent is a license awarded by the government which gives the holder exclusive rights to a process, design or innovation. Patents are issued, usually after a long application and investigation process, for a specific period of time (currently 17 years). Innovation ... it is a pathway for continuous improvement. Faurecia registers about 300 patents around the world per year. Most of this research and development is done in the Group’s 33 technical centers, where about 3,500 engineers and technicians work on everything from new vehicle concepts to new products for customers. “Being awarded a patent requires a great deal of creativity,” said Bob Kinney, Vice President of Engineering and Research & Development in North America, FIS. “It’s also a long process of proving that the challenging standards of innovation from the U.S. Patent Office are met before one is awarded.” Eight honorees On May 11, the North American Interiors Systems division recognized eight employees who have been awarded six patents during the past several years. These employees will be honored with plaques on the Innovation Wall, a place of distinction in the Auburn Hills Tech Center. This will provide lasting recognition to promote and inspire future patent contributors. “I am pleased to present these awards to our employees,” said JeanMichel Renaudie, President of FIS NAO. “You can see from this group that our innovations come from both engineering and manufacturing. It is the point that everyone needs to contribute to achieve our business goals, and innovations like this will set us apart from the competition. I look forward to presenting more awards like this.” The FIS employees who received patents were: • Steve Jones and Jeremy Lee U.S. Patent 6,641,284 “Slideable Armrest” • Mike Twork U.S. Patent 7,240,955 “Methods and Apparatus for Connecting Door Trim to a Door Module” • Andreos Kaplanov and Claude Magniez U.S. Patent 7,559,599 “Panel Side Door Structure for a Motor Vehicle” • Steve Jones and Mike Twork U.S. Patent 5,578,658 “Acoustic Chamber Integrated with Vehicle Door” •Chris McCalvin and Jeff Logan U.S. Patent 6,581,967 “Cockpit Having a Forward to Rearward Dash Plate Slip Plane” •Stephane LeTrudet U.S. Patent 6,666,362 “Cargo Management Container/Organizer Attachment Apparatus and Method” From left to right: Steve Jones, Jeremy Lee, Jean-Michel Renaudie, Mike Twork, Bob Kinney, Chris McCalvin and Stephane LeTrudet. Faurecia infos North America is a bimonthly newsletter published for Faurecia employees in the region. It provides and extends knowledge about the company, its people and activities. It delivers information about Faurecia’s processes, goals, performance and culture. May/June 2010. Copyright 2010. All rights reserved. Printed on recycled paper and uses soy-based, environmentally friendly ink. For questions, comments or article suggestions, please write to [email protected]. Editor-in-chief: Stacie Tong, Managing Editor: Christina Wootton, Contributing Editor: Marisa Fortuna
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