Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
General Presentation
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
1. Integrale Consulting
2. Services & Capabilities
3. Presence
4. Why Integrale?
5. Advantages
6. Task Force Team Readiness
7. IC’s Assets
8. Customers
9. Program Launching
10. Worldwide Experiences
11. Main contacts
INDEX
General Presentation
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
ORIGINS
Since 1982, IC has been assisting in developing and launching projects in the automotive
industry all over the World, applying the philosophy predicated by the Q101 (actual QS) Quality
Systems continuing the job started by our founder, Mr. Julio Garcia, in 1974 as Ford VEP Staff.
INTEGRALE’S DEFINITION
Integrale Consulting is a specialist in crisis management related to quality assurance. IC
capabilities cover from simple inspections through engineering changes monitoring to the most
complex repairs in engines, vehicle components and vehicle on wheels, including customer’s
team coaching to achieve best results based on our deep knowledge of the Lean Manufacturing
philosophy.
INTEGRALE CONSULTINGINDEX
CUSTOMERS
INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
OUR MISSION IS TO ASSIST COMPANIES IMPLEMENTING THE
MOST EFFICIENT SOLUTIONS TO THEIR DAILY CHALLENGES
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
Team development, Training & CoachingQuality Operating Systems
QA Management, System audits, MSA Support, Control plan assessment, G8D training, PCA’s monitoring, design capabilities, Team Coaching, etc.
Fully trained human resources and high-level engineering and equipment
Spot actions, Reworks, transport claims, 100% Inspections, capability to
design & produce specific tools, etc
NDT, Mechanic, Electric & Electronic, Painting & Body works, Machine Vision Systems Development, etc.
Subassembly, Alternative process design, Interim process execution & team
providing
Own trained engineers on the Ford QS and FPS system
Product development support & on site proactive assistance
Knowledge and experienceNew products
DEVELOPMENT OF NEW SUPPLIERSDEVELOPMENT OF NEW
SUPPLIERS
PROJECT LAUNCHING SUPPORTPROJECT LAUNCHING
INTERIM COUNTERMEASURESINTERIM
COUNTERMEASURES
PRODUCTION & QUALITY RELATED ACTIONS
REPAIRS & RETROFITSREPAIRS & RETROFITS
RESIDENT ENGINEERRESIDENT ENGINEER
SERVICES & CAPABILITIESINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
Finished components, vehicles & engines
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
Partners with more than 47 years of experience
Robotic Islands, Vehicle platforms, conveyors, Welding stations, etc.
Coaching and assessment on the implementation of Lean Manufacturing
A team of experts on the application of Lean Manufacturing through more than 30 years
Know-how and experience on machine vision system and quality systems
Own-designed and tailor made working and automatic stations based on
Machine Vision systems
Wide portfolio of engineers and technicians, own trained on the Ford QS and FPS system
Provide engineers and technicians for Project managing, project
launching, design, metrology, etc,.
DEVELOPMENT OF NEW SUPPLIERSLINE TOOLING
PROJECT LAUNCHING SUPPORTENGINEERING
OUTSOURCING
INTERIM COUNTERMEASURES
TRUE LEAN MANUFACTURING IMPLEMENTATION
RESIDENT ENGINEERAUTOMATISMS DEVELOPMENT
SERVICES & CAPABILITIESINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
¾ NEW ACTIVITIES
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SERVICES & CAPABILITIES – LINE TOOLING (1/3)INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
¾ Close cooperation with partners with more than 47 years in the business
Assembly and painting Machining and manufacturing
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SERVICES & CAPABILITIES – LINE TOOLING (2/3)INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
¾ Close cooperation with partners with more than 47 years in the business
Vehicle nominal back
Platforms
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SERVICES & CAPABILITIES – LINE TOOLING (3/3)INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
¾ Close cooperation with partners with more than 47 years in the business
Welding pallets Box side
Welding tools body side
Robotic Islands
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SERVICES & CAPABILITIES – ENGINEERING OUTSOURCINGINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
IC can provide teams of engineers and technicians, for working as intern personnel or giving support directly
stablished at the clients location. IC provides maximum flexibility on project development.
The most common services provided are:
• Product Development• Project Managers• Project Engineers• Quality Engineers• Technical metrology• CAE Simulation• Specialists in cost/weight savings• Mould Design• CAD/CAE Selection
• Organization of engineering equipment• Design of Plastic Parts• Manufacturability• Product Validation• Suppliers selection• Technical design of assembly and welding lines• …
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SERVICES & CAPABILITIES – TRUE LEAN MANUFACTURING IMPL.INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Expand IC engineering outsourcing services and our lean manufacturing coaching capabilities
Integrale Lean Solutions is a company formed by a team of experts in the coaching and management ofOrganizations to achieve the Excellence by applying the Lean Manufacturing Culture directly implemented by theemployees at all levels.
More than 30 years applying the Lean Transformation with excellent results in the Automotive industry is thegrant of our worldwide recognized experience and know-how. Our services range from one-on-one staffcoaching to management assistance, design and implementation of actuation strategies or team development.
Our innovating capabilities to implement Lean Manufacturing and tools in different businesses, industries,countries and cultures has been since our beginning, the common factor to our success and recognition.
We are experts in teaching and applying the Lean Culture and Lean Manufacturing to help organizations move forward, achieving outstanding results, conducted by the own employees and plant teams and maximizing their own and shareholder’s satisfaction as well as assuring the best future for the Business.
INTEGRALE LEAN SOLUTIONS
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
¾ IC follows a path clearly differentiated from the major part of the industry. Reinvesting in
technical resources and technologies is a standard policy
� Through the years, IC has evolved from simple visual inspections and manual reporting to
the use of modern tools, automatisms and machine vision systems, to solve the more
complex problems. All of it coordinated through our own operating systems allowing best
control of inventory, traceability data and reporting needs
Visual inspections Simple Tools On-purpose
designed toolsGauges Non-destructive tests
Automatisms and machine
vision systems
SERVICES & CAPABILITIESINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
SPAIN
UK
GERMANY
SLOVAKIA
ROMANIA
RUSSIA
PRESENCE
Headquarter
On-site facilities
Technical presence
Team
Valencia (Spain)
Valencia & Craiova Ford Plants,
UK, Germany, Slovakia, Russia, Cleveland (USA) and ChongQing (China)
100 persons - Multidiscipline Team
High qualified specialists: Inspectors, Electro-mechanics, Body/Sheet Metal
Experts, Craftsmen, Resident Engineers, Design Engineers, NDT, etc.
Along the 30+ years of existence, IC has been expanding not only in size and turnover but in
service capabilities, holding contracts and partnership with suppliers and OEMs all over the World.
INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CLEVELAND
INDEX
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
WHY INTEGRALE?
COMMITMENT
There are many reasons to choose Integrale ... which one is yours?
EXPERIENCE
COMPETENCE PROVED¾ Top Management active participation on the design,
launching & validation of every project.
¾ Outstanding proactivity guaranteed.
¾ IC’s system proved in many different fields, even in
racing engines.
¾ Reducing the time needed to start projects from
days to hours.
¾ 40 years being part of ICAs, root cause investigation,
PCAs proposal and problem solving activities.
¾ Participation in many automotive projects all over the
World.
¾ Highly familiarized with Ford’s language & procedures.
SYSTEM ROBUSTNESS
¾ Creation and training of multidisciplinary teams.
¾ Constant feedback of our work.
¾ Lesson learned retrofit.
RESULTS¾ IC’s technical capabilities world-wide recognized by the
feedback from manufacturers and suppliers, which are
our best reference.
TRUST¾ Our customer’s trust on us keeps us on the
top of the benchmark.
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
What differentiate us from our competitors? (1/2)
¾ Integrale Consulting philosophy
� Safety, team moral and order
� A constant will of adding value to our actions
� Low personnel rotation
� Top management directly involved on all projects (true inverted pyramid)
¾ Continuous reinvestment in technical and human resources
� Benchmark tools and equipment
� Continuous training of the personnel
WHY INTEGRALE?INDEX
INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
What differentiate us from our competitors? (1/2)
¾ IC mindset is to be part of the solution
� With all services presented in this profile (our core business) we pursue flawless results
¾ IC is specialized in high complexity actions
� Experts on the design of processes
� Challenging the “impossible”
¾ IC always works to close the loop
� Cover all areas, from containment actions to technical advice, consultancy and coaching to find and
solve the root cause
General Presentation
WHY INTEGRALE?INDEX
INTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
We provide you the what you need
Immediate action team
and base settlement
“Surrogate executive
capabilities”
(Attending claims,
meetings, etc.)
Minimization of the
no-quality cost
MOBILITY TIMETIME TEAM COSTCOST
ADVANTAGES
Selection
Recruitment
Training
Supervisión
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
TASK FORCE TEAM READINESS
Integrale Consulting is capable of acting at any time as an
independent operational branch of your company, ready to
be wherever you need.
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS
TRACEABILITY DATA
GATHERING BASED SYSTEM
Assuring detailed information
about jobs and parts, in real time,
thanks to our own-developed
ICOS (Integrale Consulting
Operating System).
HIGH–TECH AND
PERFORMANCE EQUIPMENT
Data capable hand tools &
gauges, endoscopes, camera
system, Own-developed Machine
Vision systems and automations,
NDT capable, etc.
PROPER MIND-SET & ATTITUDE
Basic asset to ensure best job
performance..
EDUCATION & RECURRENT
TEAM TRAINING
To assure FTT, keeping focused in
maintaining a constant improvement
mindset.
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Plan Do
CheckAct
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS – HIGH-TECH EQUIPMENT
PORE DETECTION
0
CONNECTING RODS
CAMSHAFTS
Own developed Automatisms & Machine Vision Systems
¾ Adapted to the real needs of the customers
¾ Integration and Interaction with customer systems
¾ Development of new systems in direct collaboration with customers
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS – HIGH-TECH EQUIPMENT
PISTON RINGS INSPECTION
Own developed Automatisms & Machine Vision Systems
¾ Adapted to the real needs of the customers
¾ Integration and Interaction with customer systems
¾ Development of new systems in direct collaboration with customers
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS – HIGH-TECH EQUIPMENT
Own developed Automatisms & Machine Vision Systems
¾ Adapted to the real needs of the customers
¾ Integration and Interaction with customer systems
¾ Development of new systems in direct collaboration with customers
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS - TRACEABILITY
SAMPLE OF DUMPER PULLEY’S REPLACEMENT TRACEABILITY SHEET
NOISE AUDIO RECORDING EXAMPLE (click on the image and play)
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC’s ASSETS - TRACEABILITY
SAMPLE OF BALANCESHAFT RUST INSPECTION’S TRACEABILITY SHEET
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
CUSTOMERSIC maintains long Term Relationship with the most significant Automotive Supplier
Groups/Corporations and OEMs
SUPPLIER GROUPS/CORPORATIONS� MAHLE (Valve Train, Filter Systems, Bearing,…)• EATON VALVES
• ELRINGKLINGER GROUP
• FEDERAL MOGUL (VSI, Engine Bearings, Engine
Gaskets…)
• HONEYWELL TURBO TECHNOLOGIES
• KEY SAFETY SYSTEMS
• KS KOBENSCHMIDT
• MODERN METAL &
REFINING
• ZF SACHS
• VALEO GROUP
• LINAMAR GROUP
• …
• WITTE AUTOMOTIVE
• INALFA ROOF SYSTEMS
• CHAMPION
• THYSSEN KRUPP
• FREUDENBERG
• GEBR. WIELPUETZ
OEMs• FORD BRIDGEND
• FORD DAGENHAM
• FORD DUNTON / MERKENICH / DEARBORN
• FORD VALENCIA
• FORD CRAIOVA
• GETRAG FORD TRANSMISSIONS (D,UK, SK,Mx)
• VOLVO
• OPEL
• RENAULT
• DACIA
• NISSAN
• VW
• SEAT
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
IC KEY AS SUPPORT ON PROGRAM LAUNCHING
Launching Programs & Suppliers is a significant part of IC’s Background & Assets since our founder
and actual GD function was precisely this when working for FORD back on the 70’s.
ENGINE PROGRAMS (Being part of the solutions working together with PD & Manufacturing during the launch phases)
� Zetec-SE on Cranksahfts, Camshafts and Valve Seat Inserts.
� Duratec-I4 PFI
• Camshafts, Dumper Pulleys, Valve Stem Seals (Project Launch)
• Engine Valve’s Supplier introduction (Cost saving action)
� Duractec-I4 2.0 GTDi Crankshafts and Camshafts.
� Duracted-I4 2.3 GTDi Turbocharger
� FOX 1.0 GTDi Conrods and Camshafts
VEHICLE PROGRAMS (Being part of the solutions working together with PVT & Manufacturing during the launch phases)
� C344 (C-Max) Wipers, wiper’s motors and Tailgate Latches and Servo-Motor.
� C520 (Kuga) Roof Rails, Wiper, Wiper’s motors and Moon-roofs.
� V408 (Transit) Roof Rails, Wiper, Wiper’s motors.
� CD391 (Mondeo), CD539 (S-Max), CD390 (Galaxy), Wipers, wiper’s motors, Tailgate Latches andServo-Motor, Passengers Door’s handle, Moon-roofs and Safety belts assembly.
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
WORLDWIDE EXPERIENCES
** PLEASE CLICK ON THE ACTION TO SEE DETAILED INFORMATION ON SOME OF THE EXPERIENCES LISTED ON THE PRESENT SLIDE.
• TRANSIT VAN DATA LOGGING FOR DUNTON ENGINEERING
CENTER (2002)**
• THERMOSTATS CRISI (2012)
• CAMSHAFT’S FETTLING, STRAIGHTENING & FINAL
INSPECTION (2006)**
• CONN. ROD THREAD IN ENGINE INSPECTION (2012)
• CHEMICAL RUST CLEANING ON VALVE SEAT INSERTS
(DACIA_ROMANIA) (2006)**
• CLTUCH DISCK REPLACEMENT & ALIGNMENT (2013)**
• OIL PUMP REPLACEMENT ON 18K ROCAM ENGINES (2006) • HALF SHAFT DYNAMIC STRENGTH TEST – NEAPCO (2013)
• X RAY INSPECTION ON VOLVO SI6 CATALYST (2007)** • HALFSHAFTS BEARINGS INSPECTION (2014)**
• MPS6/SPS6 GTF SLOVAKIA TRANSMISSIONS REPAIR
(2008)**
• CATALYST RUST REMOVAL (2014)**
• 2.0 GTDi PISTON CRACKING CONTAINMENT ACTION AND
CUSTOMER PROTECTION (2010)**
• BALANCESHAFTS RUST INSPECTION (2014)**
• CAMSHAFT COVERS REPLACEMENT IN FORD CHINA &
VOLVO GENT (BELGIUM) (2011)**
• MAGNEISUM INNER PANNELS INSPECTION & REWORK (2014)
• DAMPER PULLEYS IN CFMA CHONGQING PLANT (2011)** • OIL SEAL RETAINER INSPECTION ON FRONT COVERS & LOOSE
STOCK (2014)**
• OIL RING EXPANDER TIPS SORTING ON PISTONS VEP AND
LOOSE STOCK AT KSKF FRANCE (2011)**
• PISTON’S FIREWALL (2014)**
• FRONT WIPER MOTOR REFLASH (2012) • OTHERS…AND MORE
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
MAIN CONTACTS
JULIO GARCÍAGeneral Director & Chief Engineer(+34) 619 230 907 - [email protected].
VICENTE CALABUIGEngineer & Design Manager at Valencia(+34) 606 351 038 - [email protected].
ALEXANDRA SPANUDeputy Director & Controller(+34) 609 600 681 - [email protected].
ROSBELL MARTÍNEZExecutive Assistant to Mr. Julio García(+34) 616 428 970 - [email protected].
BELÉN ALEPUZBase Manager & Senior Executive at Valencia(+34) 616 460 448 - [email protected].
MADALINA RADOIBase Manager at Craiova(+40) 725 043 158 - [email protected].
ADMINISTRATION & CUSTOMER SERVICESENGINEERING & OPERATIONS
General Presentation
CARLOS MICÓAutomatisms & Machine Vision Engineer(+34) 619 583 422 – [email protected].
INDEXINTEGRALE CONSULTING
SERVICES & CAPABILITIES
PRESENCE
CUSTOMERS
WHY INTEGRALE?
ADVANTAGES
TASK FORCE
IC’s ASSETS
PROGRAM LAUNCHING
MAIN CONTACTS
WORLWIDE EXPERIENCE
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
“Thank you for your kind attention”
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
RESULTS &
BENEFITS
• The 60 Vans localized and installed in 2 weeks, meaning an average of 14.000Km, each country.
• Engine / Transmission management CPU software error found during our actions on Italian Vans.
• Ford Dunton’s congratulation for being the only team achieving 100% of the objective.
• The success of the action facilitating same action for vehicles in all Europa & South America Plants.
• ACTION SCOPE: Engine / Transmission management CPU’s data gathering on Ford Transit Vans to asses average customer
driving habits to evaluate if the engine DV Test Programs were designed in line with market demands.
• ACTION HIGHLIGHTS:
9 Action Coverage: Spain, Italy & Turkey.
9 Team training in Dunton Engineering Center.
9 Localizing the 60 vans, Data logger installation, follow up and uninstallation.
9 Downloading the gathered data to be compiled on a file for Dunton analysis. Objective: Asses 60 vans each country during the
same
• RESOURCES: All human, technical and transport resources were provided by IC.
PROJECT TRANSIT VAN DATA LOGGING FOR DUNTON ENGINEERING CENTER
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
CAMSHAFT’S FETTLING, STRAIGHTENING & FINAL INSPECTION
• Not having been able to develop and perform this action, VEP camshaft machining line would
have been unable to produce for 6 months.
• Approx. 375K camshafts successfully supplied to the machining line.
• PROBLEM DESCRIPTION: Tier 2 supplier bankruptcy without pre-advice, putting Valencia Engines Production at risk .
• ACTION SCOPE: Get the team & equipment to Perform the fettling, straightening
and visual control operations on the as cast camshafts.
• ACTION HIGHLIGHTS:
9 Tier 2 supplier announcing its bankruptcy, just before Christmas shutdown.
9 IC requested to Develop the process, equipment and team to do the above
mentioned operations on 3.750 camshafts per day.
9 Process implying 22 persons, 6 milling/grinding machines and transfer benches to
link the different operations.
9 Action to be maintained until alternative Tier 2 supplier launched or integrated at
Tier1.
9 Estimated time 6 months.
• RESOURCES: All human and technical resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
CHEMICAL RUST CLEANING ON VALVE SEAT INSERTS (DACIA_ROMANIA)
• Just one week needed to salvage 250K VSI.
• Avoided Dacia Stop Production.
• PROBLEM DESCRIPTION: All stock of VSI rusted, Brazilian supplier unable to recover/replace 2 months of stock.
• ACTION SCOPE: Organize chemical cleaning on site. Romania not being part of the EU adding additional complexity to get
equipment through customs, finding the appropriated chemicals etc.
• ACTION HIGHLIGHTS:
9 Design the process covering all potential risk having to handle corrosive chemical products requiring:
• Heatable tanks and baskets to immerge the seats from bath to bath.
• Adequate drying process.
9 Get Renault Product Engineering and Plant Safety approvals.
• RESOURCES: All human and technical resources, as well as specific equipment
provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
X RAY INSPECTION ON VOLVO SI6 CATALYST (Bridgend Engine Plant_BEP)
• Production protected.
• £17.280 saved
• PROBLEM DESCRIPTION: Crack/breakage risk on ceramic element after catalyst pallet dropped during handling.
• ACTION SCOPE: Check 144 catalyst assembly by X-ray.
• ACTION HIGHLIGHTS:
9 Prepare X-ray inspection process reproducing some “false positive” samples.
9 Coordinate process approval with Volvo Cars Engineering, STA and BEP IQ.
9 Organize affected parts transport to Bilbao (Spain) where the appropriate equipment was localized .
9 Assure traceability by collecting 3 pictures each part (X-Y-Z).
9 Total process completed in 5 days.
• RESOURCES: All human, technical and transport
resources were provided by IC.
X-Rays
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
MPS6/SPS6 GTF SLOVAKIA TRANSMISSIONS REPAIR
• 3.800 Transmission repaired.• Main customer Mitsubishi product launch EVO X protected.• IC congratulated by Plant Manager for high s cleanliness standards and area spare parts
organization.
• PROBLEM DESCRIPTION: High rejection (up to 45%) at EOL on SOP.
• ACTION SCOPE: Repair all EOL rejected transmissions until process stabilization achieved.
• ACTION HIGHLIGHTS:
9 Work instructions and job started by IC’s own resources in 1 week.
9 Local team of 18 mechanics hired and on the job trained in 10 days.
9 Working rig trolleys purchased by IC on behalf of GTF.
9 Night shift working only to avoid interferences with production.
9 Analysis of the failure mode during disassembly to facilitate the line improving the performance.
9 High interaction with GTF Management and Engineering to apply lesson learned to the process.
• RESOURCES: All human, technical and transport resources were provided by IC.
1/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
SHARING LESSONS LEARNED ON MPS6/SPS6 GTF SLOVAKIA WITH GTF IRAPUATO (MEXICO)
• Significant time and issues saving helping to flawless launch.
• PROBLEM DESCRIPTION: High rejections when launching Fiesta Dual clutch transmission.
• ACTION SCOPE: Share lessons learned in Slovakia with Irapuato team and support repairs if needed.
• ACTION HIGHLIGHTS:
9 IC recommended by GTF Slovakia.
9 IC key engineers travel to Mexico 24 hours after request.
9 Production process audit and assessment, corrective and improvement actions defined and GTF Engineering Management
updated on Slovakia’s launch lesson learned.
9 Local third Party team trained on dual clutch transmission basics.
2/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT 2.0 GTDi PISTON CRACKING CONTAINMENT ACTION AND CUSTOMER PROTECTION
• PROBLEM DESCRIPTION: Piston failed on DV test while launching 240ps 2.0GTDi engines due to sub-surface defect.
• ACTION HIGHLIGHTS:
9 Sorting pistons assembled on engines by Date Code using Endoscopy method on:
• all engines on stock at VEP by piston Date Code. 2.500 engines inspected in 2 days.
• all engines held at Ford Genk & Volvo Gent (Belgium). 250 engines inspected in 1 day.
• all engines in vehicles at Ford Genk & Volvo Gent. 850 vehicles inspected in 7 days.
9 Sorting loose pistons by eddy Current. This action was maintained over 600K pistons until supplier able to perform same Eddy
Current method on their process.
9 Sorting the engines found suspect with Endoscopy method by Eddy Currents without disassembling engines through the spark
plug hole.
• INTEGRALE’S INVENTION:
The method to perform the Eddy Current through the spark plug hole was invented, designed and manufactured by IC, having been
recognized by all parties affected: Ford, piston’s Supplier & Rohmann, worldwide Eddy Current equipment's manufacturer.
• RESOURCES: All human, technical and transport resources were provided by IC.
RESULTS &
BENEFITS
• Production stop avoided, engine stop ship cleared in 2 days, Vehicle Plants cleared in +7 days.• 750 Engines resulted NOK after endoscopy and thanks to IC’s invention additionally 735 engines were
salvaged. Approx. €4.2 million were saved, of which €1.5 thanks to the Eddy Current on finished engines. • VEP wining technical Maturiy Model Excellence Award 2010 because of the IC new EC method.
1/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
2.0 GTDi PISTON CRACKING CONTAINMENT ACTION AND CUSTOMER PROTECTION
AlignmentIndicatorNotch
Arm Rotation Knob Alignment Pin
Top View of Probe
ScanRecess
Dirk Heller (EU PTO DTOR), FORD VEP MANAGEMENT and Julio Garcia (IC`s MD)
2/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
CAMSHAFT COVERS REPLACEMENT IN FORD CHINA (ChongQing Plant) & VOLVO GENT (Belgium Plant)
• All engines were fitted avoiding any interruption on the production flow .
• CFMA Quality management Congratulated the team for outstanding job offering their support
to IC opening a branch at their factory.
• PROBLEM DESCRIPTION: High oil consumption on 2.0GTDi engine due to defective welding of baffle on camshaft cover.
• ACTION SCOPE: Replace covers on +600 vehicles at Volvo Gent and 1.850 at Ford
ChongQing Plant (China).
• RESOURCES: All human, technical and transport resources, as well as local translators,
lawyers, medical and assistant support were provided by IC.
• ACTION HIGLIGHTS:
9 Volvo job solved in 11 days including process training, traveling and job performing.
9 China job solved in 3 weeks:
• 1 week to prepare VISA and all related documents to allow 10 person and the
relevant tooling and equipment to enter in China.
• 2 weeks job preforming.
• Making suitable the working space provided by CFMA’s ELO-HAIER warehouse.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
DAMPER PULLEYS IN CFMA CHONGQING PLANT (China)
• 175 Damper pulleys replaced on finished vehicles at Ford CFMA Plant.• Rework 100% effective, no customer or market claims.
• PROBLEM DESCRIPTION: Noisy damper pulleys on vehicles needing to be replaced.
• ACTION SCOPE:
9 Perform noise check on 2.500 vehicles on wheels, segregating the ones showing “ticking” noise to replace the damper pulley. This repair implying engine timing control and adjustment.
• ACTION HIGHLIGHTS:
9 Taking advantage of the good relationship achieved with CFMA in our previous job and theexperience with needed documentation, the reaction time for this action was less than 7days.
9 The IC’s developed method including:
• Noise recording before and after replacement for best assessment traceability data byVIN numbers.
• Specific tools manufacturing to assure correct timing set up.
• Daily audios with Supplier/VEP/CFMA as IC was appointed to be the VEP Resident forthat problem in front of their customer, CFMA.
9 IC was asked by CFMA management to stay 1 more week to train their repair team in the 2.0GDTi engine. Specific tools drawings and specimen where given to them as well.
• RESOURCES: All human, technical and transport resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
OIL RING EXPANDER TIPS SORTING ON PISTONS VEP AND LOOSE STOCK AT KSKF FRANCE
• MTC Planned introduction date not delayed.
• 12.000 pistons and 250K oil rings successfully checked.
• PROBLEM DESCRIPTION: Oil ring expander defective joint angle on 2.0GTDi “value” piston.
• ACTION SCOPE: Certify all pistons in stock and transit, as well as the loose oil rings stock
(Tier2) at supplier’s facilities in France.
• ACTION HIGHLIGHTS:
9 Due to the very small dimensions (0,3mm) to be checked and the high quantity of components
to inspect, the standard inspection by magnifying glass wasn’t appropriate (high inspector
cycling, human ability dependent, reproducibility affected…).
9 A magnifying vision system by camera was implemented by IC, allowing high inspector’s
viewing comfort, reducing the total number of inspector required.
9 Method design, vision equipment availability, validation and team ready to start in 4 hrs.
• RESOURCES: All human (2 persons
per shift), technical, specific tools and
transport resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT CLUTCH DISCK REPLACEMENT AND ALIGNMENT
RESULTS & BENEFITS• 700+ engines salvaged, stop build avoided on Project SOP/ Ramp Up.
• Significant Cost saving & Final Customer Protection.
• PROBLEM DESCRIPTION: V408 Program Stop build risk due to clutch disck issue on 720 engines (DV6_DEP).
• ACTION HIGHLIGHTS:
9 The process to be applied had to warrant a replacement pace fast enough to
cover the Production Line requirements to avoid the Stop build.
9 Just five hours after go ahead needed to have the process ready and starting
the action, including:
• Centering mandrill design change and manufacturing.
• Modifying 4 racks to use them as working rigs.
• Process design and validation to allow 6 mechanics working on the same
rack.
9 Action completed in 60 hours.
9 Engine Express Shipment avoided to maintain vehicle line flow.
• RESOURCES: All human, technical and space resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
HALFSHAFTS BEARINGS INSPECTION
• 200 vehicles salvaged.
• PROBLEM DESCRIPTION: 400 half shafts are suspect due to possible bearings cracking.
• ACTION HIGHLIGHTS:
9 Penetrant Die Inspection based on Half shafts disassembly until obtain the 3
bearing set. Disassembly the 3 bearing sets and clean the 3 bearings in order
to apply the penetrant liquid and check if any crack appears.
9 Penetrant Die inspection (NDT) replaced Vision system (x25) based on
disassembly & clean the 3 bearings and check them visually.
• RESOURCES: All human, technical, NDT and vision resources were provided by
IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
CATALYST RUST REMOVAL
• 2.736 rusted parts saved.
• More than € 400.000 saved thanks to IC’s SALVAGING proposed method.
• PROBLEM DESCRIPTION: All CD-391 catalyst’s stock in Plant is rusted.
• ACTION HIGHLIGHTS:
9 Sorting organized and coordinated with external warehouse in 2 hours (Process, training, material movements, permits approval,
etc…).
9 Developing and seeking engineering approval for IC’s developed rust removal method on Catalysts.
• RESOURCES: All human, technical, purchasing and transport resources were provided by IC.
BEFORE REWORK AFTER REWORK
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
BALANCESHAFT RUST INSPECTION
• Stop Build avoided.
• 80.000 Balanceshaft salvaged at €65 ea.
• Significant saving not having air a frighted daily production (6 weeks) from Mexico.
• PROBLEM DESCRIPTION: 2.0 GTDi balance shaft found rusty on routine tier down analysis.
• ACTION SCOPE: Disassembly all balance shaft in stock and transit to check for
rusty shafts/gears.
• ACTION HIGHLIGHTS:
9 Disassembly/assembly process, designed by IC, approved by PD and
validated by VEP (Valencia Engine Plant).
9 25 technicians required to cover production demands hired and trained during
the Easter Plant shutdown.
9 Full traceability by balance shaft S/N on torques and sequence.
9 Macro created to alert in case of not all 6 torque value recorded.
• RESOURCES: All human, technical and specific tools design and manufacturing
resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT OIL SEAL RETAINER INSPECTION ON FRONT COVERS & LOOSE STOCK
• PROBLEM DESCRIPTION: VEP affected by repeated market claims and Hot Test rejections on 2.0GTDi engine for oil leaks.
PD investigation defined the cause as double trim on oil seal lip. Same problem affecting Ford USA, Mexico and China.
• ACTION SCOPE: 100% check of all Front Covers and remaining loose stock at Tier2 facilities
in France.
• ACTION HIGHLIGHTS:
9 25X Magnification required through microscope linked to light source and computer screen
to be supplied by oil seal manufacturing.
9 4 Stations/3shifts minimum required to cover daily production.
9 To overcome required equipment delays, IC provided equivalent equipment in 2 days,
accepted as interim solution by the Plant.
1/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
9 Once the supplier’s equipment received, VEP decided to uses IC’s provided system due to its higher definition and
inspector friendly conditions.
9 2 additional root causes found by the IC inspectors, thanks to the high definition of the system.
9 To minimize the high rejection rates cost effects, IC proactively developed a oil seal replacement method including
the design and manufacturing of the relevant fixtures.
9 After successfully passed through R&R, capacity studies, initial samples, line trials, etc, the method was approved
by VEP asking IC to share our method with all other Plants and to supply them with the required fixtures.
9 340K produced parts before PCA salvaged from being scrapped.
• RESOURCES: All human, technical and specific tools design and manufacturing resources were provided by IC.
PROJECT OIL SEAL RETAINER INSPECTION ON FRONT COVERS & LOOSE STOCK
RESULTS & BENEFITS
• Approx. 300K front covers inspected, zero defects claimed since firewall in effect.
• Approx. 120K loose retainers (up to 300K with our method and tooling design in USA and
Mexico.
• 15K reworked covers in VEP, under IC’s method, saved $335K. Equivalent saving should have
been achieved on the other Plants.
2/2
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General PresentationWORLDWIDE EXPERIENCES
PROJECT
RESULTS & BENEFITS
PISTON’S FIREWALL
• Supplier cleared on the Top 10 List.• IC’s lessons learned applied on supplier process to improve defective parts detection.• During the firewall, IC has developed an autonomous vision system to be applied at suppliers
EOL.
• PROBLEM DESCRIPTION: Supplier on Top10 list and biweekly quality review meetings due to frequent recurrent defects
(missing rings, overlapped expander, detachable burrs, etc…) found on the assembly line.
• ACTION SCOPE: Perform 100% check after arrival in Plant and before assembly.
• ACTION HIGHLIGHTS:
9 The method to be applied showing added complexity once defects escaped a third party firewall
at supplier site.
9 Vision system reinforced with turning tables and laser pointer.
9 Our firewall proved to be 100% effective, no defective parts found in the assembly line, having
checked 490K pistons of which 5.593 were segregated as NOK.
• RESOURCES: All human, technical and specific tools resources were provided by IC.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
General Presentation
OTHERS….
RESULTS & BENEFITS
Ultrasonic Diagnosis on CrankshaftsModern equipment is available
Penetrant Dye Crack Evaluation on PropellerRecognized in Aeronautics as well.
WORLDWIDE EXPERIENCES
Moon Roof ReplacementWeather inclemencies prevented on open
air repairs