16
DENSO Manufacturing Hungary Ltd.
DENSO Manufacturing Hungary Ltd.
2
ENVIRONMENTA society where the environmental burden of the automobile is as close to zero as possible over the entire product lifespan.
COMFORTA society in which everyone can enjoy the space in whichthey move and the time they spend doing so.
SAFETYA society without traffi c accidents,in which drivers, passengers andpedestrians can feel safe.
CONVENIENCEA prosperous automobile societywhere everyone arrives at their destinationsmoothly and stress-free.
Continuous innovation to build a sustainable automotive society
At DENSO, we work to improve the three basic functions of theautomobile: moving, turning and stopping. But that’s not all.We also strive to enhance the driving experience and to advance all aspects of the automobile society for drivers, pedestrians andthe global environment. To make this happen, we have become a leader among automobile part makers in R&D investment. In the areas of environment, safety, comfort and convenience, our technical innovation continues non-stop.
TECHNOLOGY
3
4
FORESIGHT• Vision
• Creativity• Challenge
COLLABORATION• Communication
• Teamwork• Human
development
CREDIBILITY• Quality fi rst
• On-site verifi cation• Kaizen
DENSOSpirit
DENSO’s values and principles are known as the DENSO Spirit. It is a guiding principles for all employees around the world.
Preserve the planet Security & Safety
OUR LONG-TERM MISSION
Deliver convenience and joy of drivingto the people all over the world
Maximize positive value
DENSO’s commitmentto automotive society
Minimize negative impact
THE DENSOPHILOSOPHY
All of our activities, everything we do is based on the DENSO Philosophy: Contributing to a better world by creating value together with a vision for the future.
The slogan that describes our long-term policy 2020 is: “Protecting Lives, Preserving the Planet,and Preparing a Bright Future for Generationsto Come.”
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SUBSIDIARIESJapan: 63Asia & Oceania: 56Europe: 35North-America: 26South-America: 6
GLOBAL NETWORK
Number of employees, DENSO Global
160 000
140 000
120 000
100 000
80 000
60 000
40 000
20 000
0
72 359
80 795
85 371
86 639
89 380
95 461
104 184
105 723
112 262
118 853
119 919
126 036
120 812
132 276
123 165
139 842
146 714
1998.4- 1999.3
1999.4- 2000.3
2000.4- 2001.3
2001.4- 2002.3
2002.4- 2003.3
2003.4- 2004.3
2004.4- 2005.3
2005.4- 2006.3
2006.4- 2007.3
2007.4- 2008.3
2008.4- 2009.3
2009.4- 2010.3
2010.4- 2011.3
2011.4- 2012.3
2012.4- 2013.3
2013.4- 2014.3
2014.4- 2015.3
Number of employees, DENSO Manufacturing Hungary Ltd. (including rented associates)
5 000
4 500
4 000
3 500
3 000
2 500
2 000
1 500
1 000
500
092 187 554
611
736
1 887
2 631
3 173
3 834
5 022
4 170
3 798
4 621 4 085
4 433
4 689
4 580
1998.4- 1999.3
1999.4- 2000.3
2000.4- 2001.3
2001.4- 2002.3
2002.4- 2003.3
2003.4- 2004.3
2004.4- 2005.3
2005.4- 2006.3
2006.4- 2007.3
2007.4- 2008.3
2008.4- 2009.3
2009.4- 2010.3
2010.4- 2011.3
2011.4- 2012.3
2012.4- 2013.3
2013.4- 2014.3
2014.4- 2015.3
Growth in sales turnover, DENSO Manufacturing Hungary Ltd. (million EUR)600
500
400
300
200
100
00,1 7,3
41,4 56,8 64,9
133,7
177,8
240
428
533
359
404,8
324
389,2
449
461,9
509
1998.4- 1999.3
1999.4- 2000.3
2000.4- 2001.3
2001.4- 2002.3
2002.4- 2003.3
2003.4- 2004.3
2004.4- 2005.3
2005.4- 2006.3
2006.4- 2007.3
2007.4- 2008.3
2008.4- 2009.3
2009.4- 2010.3
2010.4- 2011.3
2011.4- 2012.3
2012.4- 2013.3
2013.4- 2014.3
2014.4- 2015.3
1998.4- 1999.3
1999.4- 2000.3
2000.4- 2001.3
2001.4- 2002.3
2002.4- 2003.3
2003.4- 2004.3
2004.4- 2005.3
2005.4- 2006.3
2006.4- 2007.3
2007.4- 2008.3
2008.4- 2009.3
2009.4- 2010.3
2010.4- 2011.3
2011.4- 2012.3
2012.4- 2013.3
2013.4- 2014.3
2014.4- 2015.3
4,5
4
3,5
3
2,5
2
1,5
1
0,5
01,758
1,884
2,401
2,401
2,332
2,502
2,799
3,188
3,610
4,025
3,143
3,154
2,976
3,5803,131
4,095
4,308
Growth in sales turnover, DENSO Global (billion JPY)
6
DENSO Manufacturing Hungary Ltd.
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
HIS
TORY
ESTABLISHING BUILDINGCONSTRUCTION II. PHASE
BUILDINGCONSTRUCTION III. PHASE
COMPLETE PLANTCONSTRUCTION
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
AWA
RD
CER
TIFI
CAT
E QS9000, ISO14001
OHSAS 18001
TS 16949EUROPEANENVIRONMENT AL AWARD
HUNGARIAN ENVIRO NMENTALAWARD
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
PRO
DU
CT
ECD-V5: STARTOF THE MASSPRODUCTION
VCT
3RD GENERATION COMMON RAIL SYSTEM
SPARK PLUG
OCV
DCV2EGRVETB
7
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
BUILDINGCONSTRUCTION IV. PHASE
*COMMON RAIL
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
EUROPEANENVIRONMENT AL AWARD
HUNGARIAN ENVIRO NMENTALAWARD
STRATEGIC PARTNERSHIP AGREEMENT WITH HUNGARIAN GOVERNMENT
INVESTOR OF THE YEAR AWARD
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
GASOLINE INJECTOR
SPARK PLUG
EGTSDC-EGRV
A/F SENSORDIESEL FUEL FILTER
4TH GENERATION COMMON RAIL SYSTEMEGR UNIT
MOST EXCELLENT CSRSOLUTION OF 2015 AWARD
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[ASIA/JAPAN]
[AMERICA]
DMHU
Customers
DMHU Products Products
Diesel CommonRail System1. Supply Pump2. Rail3. Injector
3
2
1
4
8
6
7
9
10
5
11
12
FORDJAGUARLAND ROVERPERKINSTOYOTA
NISSAN
JOHN DEEREPEUGEOTRENAULTVOLVO
JOHN DEEREVW MEXICOFORD BRAZILGM DMAX
SHANGHAI-VWFAW-VWCHANGGANG-FORDFORD INDIATICONISSAN
LOMBARDINIFIATIVECO
TOYOTAFORDVOLKSWAGEN
VOLVO
AISANSKODA
SUZUKIAUDI
GM DMHU
FORDTOYOTA
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UK
E
FR CH
ROIT
TK
A
CZ
NL
PL
SK
H
DE
Suppliers(Purchase AmountShare by Country)
Other EngineRelated Products4. VCT (Variable Cam Timing)5. OCV (Oil-fl ow Control Valve)6. ETB (Electronic Throttle Body)7. EGTS (Exhaust Gas Temperature Sensor)8. DC-EGRV (Direct current - Exhaust Gas Recilculation Valve)9. A/F Sensor (Air/Fuel Sensor)10. EGR Unit (Exhaust Gas Recirculation Unit)11. Gasoline injector12. Diesel fuel fi lter
Asia & Oceania
JROKCN
RI
TVN
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Supply pumpThe light weight - aluminium housing - pump pressuresthe fuel (up to 2500 bar)upon fl uid-pressure principle and it regularizes theinjection volume withelectrical control.
InjectorThe electronically controlled injector atomizes the high-pressure fuel through precision hole in order to provide perfect combustion and directly injects the fuel into the combustion chamber.
The high pressure pump supplies up to 2500 bar pressure to the rail. Vaporization to the combustion chamber is made by the injector, which ensures that fuel is supplied in proper quantities and at an appropriate time and rate for perfect combustion.
Advantages of the system: • Reduced emission
(NOx, particles) • Simplifi ed supply pump • Enhanced injection pressure • Enhanced engine performance • Reduced fuel consumption • Long lifetime • Noise- and vibration-proof
operation of the engine
Diesel Common Rail System
PRODUCTS
Common rail Rail stores the supply pump created high pressure and distributes it to the injectors.
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Gasoline injectorThe electronically controlled injector atomizes a predetermined amount of fuel towards the intake valve.predetermined amount of fuel towards the intake valve.
Gasoline injector
EGR unitThe product integrates the features of ETB (Electronic Throttle Body) and DC-EGRV (DC Current Exhaust Gas Recirculation Valve): it simultaneously controls the amount of intake air and the amount of exhaust gas to be recirculated into the engine.
Diesel fuel fi lterThis part fi lters the fuel coming from the tank and transmits it towards the supply pump.
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DIESEL ENGINE RELATED PRODUCTSDIESEL ENGINE RELATED PRODUCTS
System Control Componentsand other products
These products make possible the perfect enginefuelling and smooth and effi cient operation of the dieselengine by controlling the injection time, fuel pressureand engine speed.
PRODUCTS
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VCT (variable cam timing)VCT controls the operation of the intake and exhaust valves and with this ensures the proper performance (torque), fuel economy in the engine and the minimal emission.
EGTS (exhaust gas temperature sensor)EGTS is to measure exhaust gas temperature.
ETB (electronic throttle body)ETB makes the electronic control of intake air possible.
OCV (oil control valve)Electro-hydraulic valve, conducts the operationof the VCT.of the VCT.
and with this ensures the proper
DC-EGRV (direct current - exhaust gas recirculation valve)Decreases the amount of the fresh intake air with tracing back the exhaust gas into the intake side in order to optimize the amount of nitrogen oxide (NOx) emission.of nitrogen oxide (NOx) emission.
A/F sensorThe sensor detects the amount of the oxygen in the exhaust gas. Using this information, air-fuel mixture burnt in the engine can be optimized.
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PROCESSPRODUCTION
INCOMING INSPECTIONIncoming parts are checked with sampling, while checking main parameters of the parts with the following processes:
• visual inspection• simple geometric measurements• precise measuring by 3D machines • contour and surface roughness check • laboratory check (hardness, microstructure)
DIE CASTING / FORGING /HEAT TREATMENTThe fully automatic technology (vacuum squeezing aluminium casting) allows low porosity cast parts to be manufactured at a high production rate. The forging process shapes the metal into the required shape by taking advantage of the plasticity and applying pressure to force it into the dies with press. In order to increase their durability and wear resistance, steel basic materials are subject to a computer-controlled heat treatment process.
MACHININGThe majority of our high precision machines are controlled by CNC technology. Applying the most recent grinding process keeps the concentricity of the pieces within a tolerance of less than 0.5 micrometers. With the multi-spindle and multi-axis high precision machines more operations can be made on one piece at one time. Machines are controlled by CNC technology. After the fi nishing cut the surfaces are grinded into the required size with the most recent grinding process keeps the roughness of the pieces within a tolerance of less than 0.5 micrometers.
ASSEMBLING
The semi-automated fi nal assembly lines can be found in air conditioned rooms. Each important part runs through a „foolproof” system to eliminate any human error and it is continuously gauged in order to ensure perfect quality. Assembly robots and visual recognition systems are also used in this area.
Production fl owINCOMING INSPECTION DIE CASTING / FORGING / HEAT TR EATMENT MACHINING ASSEMBLY MEASURING PERFORMANCE TEST FINAL INSPECTION
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MEASURING
In the precision measuring room where the constant temperature and humidity assures the standard size of the parts, technicians use high accuracy(0.1 micrometer) coordinate measuring machines to check the quality of the production processes. These measuring and testing routines ensure that even the smallest deviation in quality is recognized and corrected.
PERFORMANCE TEST
During the test the individual operating parameters of the fuel pumps and injectors are metered and encoded in each product at different rotational speeds and pressures during a computer controlled process. Using these parameters, the electronic engine controller adjusts the injected fuel volume and timing optimally for engine performance and European environmental standards.
FINAL INSPECTION High qualifi ed inspectors carry out 100% visual check. Beside this they inspect the threads and positions that are important for the customer with gauges. Finally with the matching of the QR codes of the fi nished products, the process control card and the box, what ensures to prevent type mixing or mislabeling, they forward the fi nished parts to the warehouse.
INCOMING INSPECTION DIE CASTING / FORGING / HEAT TR EATMENT MACHINING ASSEMBLY MEASURING PERFORMANCE TEST FINAL INSPECTION
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SAFETY & ENVIRONMENT
Safety and environmental protection has a special role at DENSO Manufacturing Hungary Ltd., we have an independent department for these tasks. Our company policy is ‘Safety and quality fi rst’. To fulfi ll the policy we issue annual safety and environmental plan based on the past years trends and also including DENSO corporation requirements. This plan is evaluated on a monthly base. We carry out regular risk assessment, safety inspections and safety training in all levels. We have implemented monthly Top Management safety patrol since 2010.We operate occupational health service and we carry out regular working environmental measuring to protect our associates’ health. We have elected safety committee since 2004.Regarding environmental protection, we pay special attention to the selective waste handling, to decrease emission and to the energy saving.
CORPORATE SOCIAL RESPONSIBILITY
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At DENSO we think that it’s really important to contribute to the sustainable development of our environment and society. In order to realize this we strive to contribute to the harmonic development with our active environmental and donation programs beside our fair and transparent business activity.
We not only pay attention to the satisfaction of our external parties but our employees’ happiness and development is also really important. In order to realize this, DENSO Foundation operates since 2011. Aim of the Foundation is to give fi nancial support to our associates in such cases when they involuntarily and suddenly get into a serious life situation.
It’s an emphasized aim of our CSR policy to create lasting values in our nearer environment while we contribute the satisfaction of our interested parties. We strive to fi nd partners regarding our initiatives. Among other things KÉPES CSR Program was created also this way. This program was started upon DENSO’s initiatives in 2013 with the cooperation of local companies and the local government. Our aim is to realize aims that serve the development and satisfaction of the society of the city and the region.
One main element of our CSR activity is the active relationship with high schools and universities. It’s really important to help the future generation and to contribute to their development. Beside our university trainee program, we take part in the dual education system for vocational school students as company for professional practice. In the frame of plant tours and professional presentations we regularly provide opportunity to the professionals of the future to get knowledge about our company’s processes.
DENSO Manufacturing Hungary Ltd.Holland Fasor 14. SzékesfehérvárH-8000 HungaryE-mail: [email protected]: www.denso-local.com/hungaryPublished in 2015 D
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