General Presentation Ed.7 Created by:J. Garca, Date:27/05/2015 , - - PowerPoint PPT Presentation
General Presentation General Presentation Ed.7 Created by:J. Garca, Date:27/05/2015 , Approved by: J.Garca, Date: May. 2015, Updated by: C. Mic Date: March 2017 General Presentation General Presentation 1. Integrale Consulting 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
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
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
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
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.
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CUSTOMERS INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE 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
Team development, Training & Coaching
Quality 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 experience New products
DEVELOPMENT OF NEW SUPPLIERS
DEVELOPMENT OF NEW SUPPLIERS
PROJECT LAUNCHING SUPPORT
PROJECT LAUNCHING
INTERIM COUNTERMEASURES
INTERIM COUNTERMEASURES PRODUCTION & QUALITY RELATED ACTIONS
REPAIRS & RETROFITS
REPAIRS & RETROFITS
RESIDENT ENGINEER
RESIDENT ENGINEER
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
Finished components, vehicles & engines
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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
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,
Provide engineers and technicians for Project managing, project launching, design, metrology, etc,.
DEVELOPMENT OF NEW SUPPLIERS
LINE TOOLING
PROJECT LAUNCHING SUPPORT
ENGINEERING OUTSOURCING
INTERIM COUNTERMEASURES
TRUE LEAN MANUFACTURING IMPLEMENTATION
RESIDENT ENGINEER
AUTOMATISMS DEVELOPMENT
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
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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
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
INDEX
CUSTOMERS WHY INTEGRALE? ADVANTAGES TASK FORCE IC’s ASSETS PROGRAM LAUNCHING MAIN CONTACTS WORLWIDE EXPERIENCE
Close cooperation with partners with more than 47 years in the business
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
INDEX
CUSTOMERS WHY INTEGRALE? ADVANTAGES TASK FORCE IC’s ASSETS PROGRAM LAUNCHING MAIN CONTACTS WORLWIDE EXPERIENCE
Close cooperation with partners with more than 47 years in the business
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
INDEX
CUSTOMERS WHY INTEGRALE? ADVANTAGES TASK FORCE IC’s ASSETS PROGRAM LAUNCHING MAIN CONTACTS WORLWIDE EXPERIENCE
Close cooperation with partners with more than 47 years in the business
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
INTEGRALE 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:
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
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 of Organizations to achieve the Excellence by applying the Lean Manufacturing Culture directly implemented by the employees at all levels. More than 30 years applying the Lean Transformation with excellent results in the Automotive industry is the grant of our worldwide recognized experience and know-how. Our services range from one-on-one staff coaching 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.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
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 tools Gauges Non-destructive tests Automatisms and machine vision systems
INTEGRALE CONSULTING SERVICES & CAPABILITIES PRESENCE
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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
SPAIN UK GERMANY SLOVAKIA ROMANIA RUSSIA
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
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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
COMMITMENT There are many reasons to choose Integrale ... which one is yours? EXPERIENCE COMPETENCE PROVED
Top Management active participation on the design, launching & validation of every project. Outstanding proactivity guaranteed. IC’s system proved in many different fields, even in racing engines. Reducing the time needed to start projects from days to hours. 40 years being part of ICAs, root cause investigation, PCAs proposal and problem solving activities. Participation in many automotive projects all over the World. Highly familiarized with Ford’s language & procedures.
SYSTEM ROBUSTNESS
Creation and training of multidisciplinary teams. Constant feedback of our work. Lesson learned retrofit.
RESULTS
IC’s technical capabilities world-wide recognized by the feedback from manufacturers and suppliers, which are
TRUST
Our customer’s trust on us keeps us on the top of the benchmark.
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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
What differentiate us from our competitors? (1/2)
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) Continuous reinvestment in technical and human resources Benchmark tools and equipment Continuous training of the personnel
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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
What differentiate us from our competitors? (1/2)
IC mindset is to be part of the solution With all services presented in this profile (our core business) we pursue flawless results IC is specialized in high complexity actions Experts on the design of processes Challenging the “impossible” 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
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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
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 TIME TIME TEAM COST COST
Selection Recruitment Training Supervisión
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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
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
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.
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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
PORE DETECTION CONNECTING RODS CAMSHAFTS
Own developed Automatisms & Machine Vision Systems
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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
PISTON RINGS INSPECTION
Own developed Automatisms & Machine Vision Systems
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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
Own developed Automatisms & Machine Vision Systems
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
SAMPLE OF DUMPER PULLEY’S REPLACEMENT TRACEABILITY SHEET NOISE AUDIO RECORDING EXAMPLE (click on the image and play)
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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
SAMPLE OF BALANCESHAFT RUST INSPECTION’S TRACEABILITY SHEET
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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
IC maintains long Term Relationship with the most significant Automotive Supplier Groups/Corporations and OEMs
SUPPLIER GROUPS/CORPORATIONS
Gaskets…)
REFINING
OEMs
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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
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
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 and Servo-Motor, Passengers Door’s handle, Moon-roofs and Safety belts assembly.
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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
WORLDWIDE EXPERIENCES
** PLEASE CLICK ON THE ACTION TO SEE DETAILED INFORMATION ON SOME OF THE EXPERIENCES LISTED ON THE PRESENT SLIDE.
CENTER (2002)**
INSPECTION (2006)**
(DACIA_ROMANIA) (2006)**
(2008)**
CUSTOMER PROTECTION (2010)**
VOLVO GENT (BELGIUM) (2011)**
STOCK (2014)**
LOOSE STOCK AT KSKF FRANCE (2011)**
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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
JULIO GARCÍA General Director & Chief Engineer (+34) 619 230 907 - julio_garcia@integrale.es. VICENTE CALABUIG Engineer & Design Manager at Valencia (+34) 606 351 038 - vicente_calabuig@integrale.es. ALEXANDRA SPANU Deputy Director & Controller (+34) 609 600 681 - andra@integrale.es. ROSBELL MARTÍNEZ Executive Assistant to Mr. Julio García (+34) 616 428 970 - rosbell@integrale.es. BELÉN ALEPUZ Base Manager & Senior Executive at Valencia (+34) 616 460 448 - belen@integrale.es. MADALINA RADOI Base Manager at Craiova (+40) 725 043 158 - madalina@integrale.es.
ADMINISTRATION & CUSTOMER SERVICES ENGINEERING & OPERATIONS
CARLOS MICÓ Automatisms & Machine Vision Engineer (+34) 619 583 422 – carlos_mico@integrale.es.
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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
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
RESULTS & BENEFITS
driving habits to evaluate if the engine DV Test Programs were designed in line with market demands.
Action Coverage: Spain, Italy & Turkey. Team training in Dunton Engineering Center. Localizing the 60 vans, Data logger installation, follow up and uninstallation. Downloading the gathered data to be compiled on a file for Dunton analysis. Objective: Asses 60 vans each country during the same
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS CAMSHAFT’S FETTLING, STRAIGHTENING & FINAL INSPECTION
have been unable to produce for 6 months.
and visual control operations on the as cast camshafts.
Tier 2 supplier announcing its bankruptcy, just before Christmas shutdown. IC requested to Develop the process, equipment and team to do the above mentioned operations on 3.750 camshafts per day. Process implying 22 persons, 6 milling/grinding machines and transfer benches to link the different operations. Action to be maintained until alternative Tier 2 supplier launched or integrated at Tier1. Estimated time 6 months.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS CHEMICAL RUST CLEANING ON VALVE SEAT INSERTS (DACIA_ROMANIA)
equipment through customs, finding the appropriated chemicals etc.
Design the process covering all potential risk having to handle corrosive chemical products requiring:
Get Renault Product Engineering and Plant Safety approvals.
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS X RAY INSPECTION ON VOLVO SI6 CATALYST (Bridgend Engine Plant_BEP)
Prepare X-ray inspection process reproducing some “false positive” samples. Coordinate process approval with Volvo Cars Engineering, STA and BEP IQ. Organize affected parts transport to Bilbao (Spain) where the appropriate equipment was localized . Assure traceability by collecting 3 pictures each part (X-Y-Z). Total process completed in 5 days.
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS MPS6/SPS6 GTF SLOVAKIA TRANSMISSIONS REPAIR
Work instructions and job started by IC’s own resources in 1 week. Local team of 18 mechanics hired and on the job trained in 10 days. Working rig trolleys purchased by IC on behalf of GTF. Night shift working only to avoid interferences with production. Analysis of the failure mode during disassembly to facilitate the line improving the performance. High interaction with GTF Management and Engineering to apply lesson learned to the process.
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS SHARING LESSONS LEARNED ON MPS6/SPS6 GTF SLOVAKIA WITH GTF IRAPUATO (MEXICO)
IC recommended by GTF Slovakia. IC key engineers travel to Mexico 24 hours after request. Production process audit and assessment, corrective and improvement actions defined and GTF Engineering Management updated on Slovakia’s launch lesson learned. 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
WORLDWIDE EXPERIENCES
PROJECT 2.0 GTDi PISTON CRACKING CONTAINMENT ACTION AND CUSTOMER PROTECTION
Sorting pistons assembled on engines by Date Code using Endoscopy method on:
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. Sorting the engines found suspect with Endoscopy method by Eddy Currents without disassembling engines through the spark plug hole.
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.
RESULTS & BENEFITS
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS 2.0 GTDi PISTON CRACKING CONTAINMENT ACTION AND CUSTOMER PROTECTION
Alignment Indicator Notch Arm Rotation Knob Alignment Pin Top View
Scan Recess
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS CAMSHAFT COVERS REPLACEMENT IN FORD CHINA (ChongQing Plant) & VOLVO GENT (Belgium Plant)
to IC opening a branch at their factory.
ChongQing Plant (China).
lawyers, medical and assistant support were provided by IC.
Volvo job solved in 11 days including process training, traveling and job performing. China job solved in 3 weeks:
relevant tooling and equipment to enter in China.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS DAMPER PULLEYS IN CFMA CHONGQING PLANT (China)
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.
Taking advantage of the good relationship achieved with CFMA in our previous job and the experience with needed documentation, the reaction time for this action was less than 7 days. The IC’s developed method including:
VIN numbers.
that problem in front of their customer, CFMA. IC was asked by CFMA management to stay 1 more week to train their repair team in the 2.0 GDTi engine. Specific tools drawings and specimen where given to them as well.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS OIL RING EXPANDER TIPS SORTING ON PISTONS VEP AND LOOSE STOCK AT KSKF FRANCE
Certify all pistons in stock and transit, as well as the loose oil rings stock (Tier2) at supplier’s facilities in France.
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…).
viewing comfort, reducing the total number of inspector required. Method design, vision equipment availability, validation and team ready to start in 4 hrs.
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
WORLDWIDE EXPERIENCES
PROJECT CLUTCH DISCK REPLACEMENT AND ALIGNMENT RESULTS & BENEFITS
The process to be applied had to warrant a replacement pace fast enough to cover the Production Line requirements to avoid the Stop build. Just five hours after go ahead needed to have the process ready and starting the action, including:
rack. Action completed in 60 hours. Engine Express Shipment avoided to maintain vehicle line flow.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS HALFSHAFTS BEARINGS INSPECTION
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. Penetrant Die inspection (NDT) replaced Vision system (x25) based on disassembly & clean the 3 bearings and check them visually.
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS CATALYST RUST REMOVAL
Sorting organized and coordinated with external warehouse in 2 hours (Process, training, material movements, permits approval, etc…). Developing and seeking engineering approval for IC’s developed rust removal method on Catalysts.
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
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS BALANCESHAFT RUST INSPECTION
rusty shafts/gears.
Disassembly/assembly process, designed by IC, approved by PD and validated by VEP (Valencia Engine Plant). 25 technicians required to cover production demands hired and trained during the Easter Plant shutdown. Full traceability by balance shaft S/N on torques and sequence. Macro created to alert in case of not all 6 torque value recorded.
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
WORLDWIDE EXPERIENCES
PROJECT OIL SEAL RETAINER INSPECTION ON FRONT COVERS & LOOSE STOCK
PD investigation defined the cause as double trim on oil seal lip. Same problem affecting Ford USA, Mexico and China.
in France.
25X Magnification required through microscope linked to light source and computer screen to be supplied by oil seal manufacturing. 4 Stations/3shifts minimum required to cover daily production. To overcome required equipment delays, IC provided equivalent equipment in 2 days, accepted as interim solution by the Plant.
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Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
Once the supplier’s equipment received, VEP decided to uses IC’s provided system due to its higher definition and inspector friendly conditions. 2 additional root causes found by the IC inspectors, thanks to the high definition of the system. 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. 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. 340K produced parts before PCA salvaged from being scrapped.
PROJECT OIL SEAL RETAINER INSPECTION ON FRONT COVERS & LOOSE STOCK RESULTS & BENEFITS
Mexico.
been achieved on the other Plants.
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Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
WORLDWIDE EXPERIENCES
PROJECT RESULTS & BENEFITS PISTON’S FIREWALL
EOL.
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.
The method to be applied showing added complexity once defects escaped a third party firewall at supplier site. Vision system reinforced with turning tables and laser pointer. 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.
Ed.7 Created by:J. García, Date:27/05/2015 , Approved by: J.García, Date: May. 2015, Updated by: C. Micó Date: March 2017
OTHERS…. RESULTS & BENEFITS Ultrasonic Diagnosis on Crankshafts Modern equipment is available Penetrant Dye Crack Evaluation on Propeller Recognized in Aeronautics as well.
WORLDWIDE EXPERIENCES
Moon Roof Replacement Weather inclemencies prevented on open air repairs