BOSCH Bari Plant - KalDer · 2017-08-12 · Robert Bosch S.p.A. PTIP (PT) Freud S.p.A.Bosch PTIM...

Internal | BarP/MFG -/DBE | 04/02/2015 | © Robert Bosch GmbH 2014. All rights reserved, also regarding any disposal, exploitation,

reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

BOSCH Bari Plant

Always one step ahead

Mariano Cilenti

Director Manufacturing

1



BOSCH Bari Plant

Bari Plant Overview

Who we are

What do we produce

What characterise us

Create a sustainable future

Managing with agility

Succeeding through the talent of people

2

PTIT (PT)

Aresi S.p.A.

VHIT (DS)

VHIT S.p.A.

CHIT (AA)

Holger Christiansen Italia S.r.l.

SCIT (AA)

Sicam S.r.l.

STIT (ST)

Bosch Security Systems S.p.A.

TDIT (DS, CC)

Tecnologie Diesel e Sistemi Frenanti S.p.A.

CVIT (DS)

Centro Studi Componenti per Veicoli S.p.A.

RBIT

Robert Bosch S.p.A.

PTIP (PT) Freud S.p.A.

PTIM (PT) Freud Produzioni Industriali S.p.A.

DCIT (DC)

Bosch Rexroth S.p.A.

ASIT/ASIM (SE)

Aleo Solar Italia Srl

UBK – Tecnica per autoveicoli

UBI – Tecnologia industriale

UBG – Beni di consumo

UBE – Settore Energia e Tecnologie costruttive

PERBIT Robert Bosch GmbH

Branch in Italy

PEETIT ETAS GmbH

Branch in Italy

SXIC (AA)

Deca S.r.l.

BARI

MILANO

TORINO

BERGAMO

TREVISO

UDINE

CREMONA

BOLOGNA

ROMA

REGGIO E.



MODENA

BEIT (BEBS)

Bosch Energy and Building

Solutions Italy S.r.l.

2013

Sales 1,8 mld. EUR

19 legal entities

5.848 associated 1)

BOSCH Bari Plant

(1) State 1.1.2014

SXIT (AA)

Bosch Automotive Service Solutions S.r.l.

DCOC (DC)

Bosch Rexroth Oil Control S.p.A.

3



BOSCH Bari Plant

Bosch Bari - Location Overview Bosch Bari

Business:

Bari Plant: Manufacturing of high

pressure pumps and

brakes

Development: Component development,

customer and serial

support

Engineering and

application of Common

Rail systems

Employees:

Plant: ca. 2000

Development: ca. 200

History

1994: Foundation of Tecnologie

Diesel Italia SpA

1996: Acquisition of Brakes

Business from Allied Signal

1998: SOP CP1

2003: SOP CP1H

2006: Nomination as model plant

for BPS in DS

2010: Bosch Quality Award

2011: BPS Award “Overall”

2012: EFQM Prize “Management

by processes”

2013: SOP Gear Pump

2013: BPS Award “Deliver”

2014: ALP Award category

international group

2014: EFQM Award and Triple

Prize winner

CC Products

ZOH (Front Brake)

BIRIII (Rear Brake)

DS Products

CP1H: 1600 bar

CP1: 1350 bar

Gear Pump

4



BOSCH Bari Plant

5

Bari & Bosch: a success story of technological evolution from

Southern Italy



BOSCH Bari Plant

The birthplace of Common Rail

First car equipped with Bosch Common Rail in the early 1990’s

6



BOSCH Bari Plant

Social-economic context of Bosch Bari in Apulia

Main opportunities

Large availability of technical

graduates and professionals

Good academic basis for science

and technology in universities

Determination of the region to

support industrial activities

Main challenges

GDP2012 per capita:

66,5% of Italian average

Unemployment rate2014: ~20%

Unemployment rate of people

under 25 years: ~40%

Building opportunities in a challenging environment

7



Strong Focus on Operational Excellence

New products

Quality

Cost

Delivery

Sustained performance

Operational

Excellence

1,16 1,21 1,211,27

1,35 1,391,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013

Productivity [pcs/h]

9798 99

100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013

On Time Delivery [%]

2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013

Inventory - TCT [Days]

2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013

Failure cost [% of PPC]

0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013

BPS Maturity level (*)

BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

1,16 1,21 1,211,27

1,35 1,391,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


9798 99

100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

1,16 1,21 1,211,27

1,35 1,391,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


9798 99

100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

1,16 1,21 1,211,27

1,35 1,391,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


9798 99

100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

Quality

Award 2010 EFQM Prize

2012

BPS Awards

2011, 2013

BOSCH Bari Plant

8



The Strategic Planning Circle

Strategy

Review

Strategic

Analysis

Strategy

Development

Strategy

Deployment

and Target

Definition

Target

Deployment

Strategic

Planning

Circle

• Stakeholder Analysis

• Competitor Analysis

• SWOT Analysis

• Vision

• Business Plan

• Balanced Scorecard

• Individual Targets

BOSCH Bari Plant

9



BarP Strategy & R2E

Performance

Improvement

Breakthrough in Profitability Increase

Leadership to

challenge and deliver

Competent employees

working with passion

Technology competence

for our future

Preferred partner

in society

Agile resource

management

Continuous outperformance

of targets

Marketing for new

products and customers

Cost innovation for

products and processes

Responsiveness to

customer demands

Living Lean,

improving fast

We challenge and deliver

BOSCH Bari Plant

10



BarP Strategy & R2E

Performance

Improvement


Leadership to


Competent employees



for our future

Preferred partner

in society

Agile resource

management


of targets

Marketing for new


Cost innovation for


Responsiveness to

customer demands

Living Lean,

improving fast


BOSCH Bari Plant

11



BarP Strategy & R2E

Performance

Improvement


Leadership to


Competent employees


Preferred partner

in society

Agile resource

management


of targets

Marketing for new


Cost innovation for


Responsiveness to

customer demands

Living Lean,

improving fast



for our future

BOSCH Bari Plant

12

Internal | BarP/MFG, -/DBE | 04/02/2015 | © Robert Bosch GmbH 2014. All rights reserved, also regarding any disposal, exploitation,


R2E Organization

Strategy Core Team

Plant Management, Finance, Production, Logistics

Leadership to

challenge and

deliver

Finance

Competent

employees

working with

passion

HR

Technology

competence for

our future

Tech.

Functions

Living lean,

improving fast

BPS

“Road to Excellence” Teams

Agile resource

management

Production

Respons. to

customer

demands

Production

Cost innovation

for products

and processes

Production

Marketing for

new products

and customers

Logistics

Preferred

partner in

society

HSE

Continuous

outperformance

of targets

Production

BOSCH Bari Plant

R2E led by Function Managers; teams built with no additional resources

13

Corporate Social Responsibility: mutual benefits for Society and Bosch



BOSCH Bari Plant

Bari Plant Social Charter B

ene

fits

for

Bosch

Bari

Be

ne

fits

fo

r S

ocie

ty Environment

Health & Safety

Waste

Collection

Green

School

Linea

Verde

Voluntary

Teams

Environmental

savings

Employer

Branding

Associates

empowerment

Partnership with

Universities and Schools

Innovative

solutions Associates

proudness

Increase associates

competence and qualification

Green

School

Emissions

reduction

Near

Miss

Lower

absenteeism Better performance by

healthy people

Employer

branding

Safety & Health

conditions Voluntary

Teams

Dual education

system

Best practice

sharing

Regional key

players’ support

CO2 reduction

projects

Sponsorships – Donations

(Scolarships) Competence

14



BOSCH Bari Plant

Environment

Environmental activities and education

15

VIDEO

Linea Verde & Green school-r.mp4

Better working conditions, healthier lifestyle



BOSCH Bari Plant

Health & Safety

16

Partnerships and cooperations with universities and schools



BOSCH Bari Plant

Competence

Introducing the dual education model in Southern Italy

17



Lean acting for operational excellence : BPS+VSDiA

Bosch Production System

is a lean oriented production

system based on 8

“elements”

Value Stream Design in

Indirect Areas applies to

indirect areas same

concepts as BPS does in

direct areas

BOSCH Bari Plant

18


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BOSCH Bari Plant

EEA Award



BOSCH Bari Plant

20

Productivity

benchmarking

Delivery Rate

benchmarking

6,60

0,90

8,30

6,10 8,

00

7,90

-10,0

-8,0

-6,0

-4,0

-2,0

0,0

2,0

4,0

6,0

8,0

10,0

6

2

1

4

3

1

4

2

1

6 VxP

JhP

n/a

n/a5

Target

YTD n/a

n/a2008 2009 2010 2013

BarP ranking

%

5

4

5 5

3 3

66

2

4 DaeP n/a

3 BanP -16,0%

2 FeP 5,8%

4

3

1

2011

5

6

2

4

3

1

2012

5

6

2

BarP

Ranking in DS

7,9%1

v

v

Ranking in DS [%]

1 B arP 100

1 R B T R 100

1 R zP 100

2 F eP 99,84

3 VH IT 99,32

4 R B C B 99,21

5 LOG11 99,04

6 H lP 98,65

7 H o P 1 98,16

8 JhP 97,95

9 B aP 84,96

10 C hP 0

YT D D S 97,61

T arget 97,50

99,9

7

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

100,0

0

98,50 98,50 100,00 100,00

0

10

20

30

40

50

60

70

80

90

100

BarP YTD BarP Target

11

9

8

7

5

4

3

2

1

6

12

11

10

9

8

7

5

4

1

6

12

11

9

8

7

5

4

2

1

6

3

12

10

Jan Feb

2010 2011 2012

Mar Apr May Jun Jul Aug Sep Oct Nov Dec YTD

2013

%

1

22

3

10

2

1

V

v



BOSCH Bari Plant

Shaping the future

MiniMAG: target deployment at workshop level

Holistic communication: Well thought thru and measured by dedicated

survey

IDEA System: Promoting good ideas at every level with lean approach

Italian language for foreigners: winning culture mix between local and

german associates

21



BOSCH Bari Plant

Always one step ahead

22

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BOSCH Bari Plant - KalDer · 2017-08-12 · Robert Bosch S.p.A. PTIP (PT) Freud S.p.A.Bosch PTIM...

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