Sürdürülebilir Bir Gelecek Yaratma, Çeviklikle Yönetme, Çalışanların Yetenekleriyle Başarma Mariano Cilenti BOSCH Bari İtalya, Kalite Müdürü

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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
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reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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
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3. 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.
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.
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.
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4. 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
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
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5. 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
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6. Bari & Bosch: a success story of technological evolution from
Southern Italy
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
The birthplace of Common Rail
First car equipped with Bosch Common Rail in the early 1990’s
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7. 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
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
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8. 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.
Strong Focus on Operational Excellence
New products
Quality
Cost
Delivery
Sustained performance
Operational
Excellence
,16 1,21 1,21
1,27
1,35 1,39
1,5
007 2008 2009 2010 2011 2012 2013
Productivity [pcs/h]
97
98 99
100 100 100 100
2007 2008 2009 2010 2011 2012 2013
OnTime Delivery[%]
28
33
25
21 20 19 17
10
20
30
40
2007 2008 2009 2010 2011 2012 2013
Inventory -TCT [Days]
2,21
1,66
0,82
0,42 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(*)
BPSAward
Winner
(Overall)
BPSAward
Winner
(Deliver)
1,16 1,21 1,21
1,27
1,35 1,39
1,5
1
1,2
1,4
1,6
2007 2008 2009 2010 2011 2012 2013
Productivity [pcs/h]
97
98 99
100 100 100 100
90
95
100
2007 2008 2009 2010 2011 2012 2013
On Time Delivery [%]
28
33
25
21 20 19 17
10
20
30
40
2007 2008 2009 2010 2011 2012 2013
Inventory -TCT [Days]
2,21
1,66
0,82
0,42 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 1,21
1,27
1,35 1,39
1,5
1
1,2
1,4
1,6
2007 2008 2009 2010 2011 2012 2013
Productivity [pcs/h]
97
98 99
100 100 100 100
90
95
100
2007 2008 2009 2010 2011 2012 2013
On Time Delivery [%]
28
10
20
30
40
200
2,21
0
1
2
3
2007 2
F
0
1
2
3
4
2007 2008 2009 2010 2011 2012
BPS Maturity level (*)
BPS Award
Winner
(Overall)
BP
W
(D
1,16 1,21 1,21
1,27
1,35 1,39
1,5
1
1,2
1,4
1,6
2007 2008 2009 2010 2011 2012 2013
Productivity [pcs/h]
97
98 99
100 100 100 100
95
100
OnTime Delivery [%]
0
1
2
3
4
2007 2008 2009
BPS M
Quality
Award 2010
EFQM Prize
2012
BPS Awards
2011, 2013
BOSCH Bari Plant
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9. 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.
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
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10. 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.
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
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11. 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.
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
11

12. 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.
BarP Strategy & R2E
Performance
Improvement
Breakthrough in Profitability Increase
Leadership to
challenge and deliver
Competent employees
working with passion
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
Technology competence
for our future
BOSCH Bari Plant
12

13. 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.
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
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14. Corporate Social Responsibility: mutual benefits for Society and Bosch
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
Bari Plant Social CharterBenefitsforBoschBari
BenefitsforSociety
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
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15. 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
Environment
Environmental activities and education
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VIDEO

16. Better working conditions, healthier lifestyle
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
Health & Safety
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17. Partnerships and cooperations with universities and schools
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
Competence
Introducing the dual education model in Southern Italy
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18. 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.
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
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19. 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.
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BOSCH Bari Plant
EEA Award

20. 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
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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
99,97
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
100,00
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

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reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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
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22. 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
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