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Target: Zero Defect
INA Skalica, INA Kysuce Fit for Quality Project
Fit for Quality Academy
30. 6. 2014 INA Kysuce, a.s. Page 1
Kysucké Nové Mesto
Region Žilina Number of inhabitants 15,680 Industry Mechanical engineering
Kalvária
Skalica
Region Trnava Number of inhabitants 15,013 Industry Mechanical engineering and paper industry
INA Skalica est.1991 4620 employees
INA Kysuce est.1999 4017 employees
30. 6. 2014 INA SKALICA spol. s r.o.
INA Skalica building phases Total production area: 77,400 m2
G01
G02
G03
G04 G06
1997 12,000 m2
G01 1999 12,000 m2
G02 2007 27,000 m2
G06 2004 6,400 m2
G04 2002 20,000 m2
G03
2a
2000 19 108 m2 1 2003
22 849 m2 2 2006 3 574 m2 4 2005
35 484 m2 3 2007 4 133 m2 5
1
2
3 4
5
30. 6. 2014 Page 3
2012 4 614 m2 2a
INA Kysuce, spol. s r.o.
INA Kysuce building phases Total production area: 92,053 m2
Wheel bearing unit with sensor
Taper roller bearing Tandem angular
contact ball bearings
Bucket tappet Camshaft adjuster
Finger follower with hydraulic pivot element
Needle roller bearing
Overrunning alternator pulley
Chain tension system
Strut bearing
Switching unit
Lightweight balancer shaft with rolling bearing supports
Toothed chain timing drive
Ball screw Torque converter
Clutch release system
Dual-mass flywheel
SAC
Double clutch systems dry/wet
Clutch linings
Transmission components
Alle
Rec
hte
vorb
ehal
ten
für L
uK, i
nsbe
sond
ere
für d
en F
all e
iner
Sch
utzr
ech
Engine and transmission components
Components for clutch and transmission systems
Wheel modules and transmission bearings
Wheel bearing with face spline
Deep groove ball bearing
Products made in ILS and IWK
30. 6. 2014 INA SKALICA spol. s r.o. Page 6
Production program Segment 02 (B) Product line 10 Needle bearings Products IR, LR, KI F-, flanged rings Main customers GETRAG GETRIEBE VW, SEAT, ŠKODA ZF, FORD, SKF, DAIMLER
Segment manager Ľudovít Musil
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Industrial
30. 6. 2014 INA SKALICA spol. s r.o. Page 8
Production program Segment 04 (D) Product line 03 Compensating elements Product line 10 Needle bearings Product line 13 Track rollers, support rollers Products NK, NKI, RNA, NA, RNAO, NAO, NKS, NKIS, NKIA, NKIB, NX, NKX, NKXR, RSTO, STO, RLB, GLB F-, IR, AGWL Main customers VW, GEARBOX, ŠKODA, BMW, SCANIA, ZF, DAIMLER, AUDI, BOSCH, KARL MAYER
Segment manager Peter Stašek
30. 6. 2014 Page 8
Industrial
30. 6. 2014 INA SKALICA spol. s r.o. Page 9
Production program Segment 05 (E) Product line 26 Axial needle bearings Products RG, SS, WS, GS, LS, ZS, TWA, TWD, VRS, AR, SSL Main customers INA-COMPANIES, ZF, VW, HYUNDAI, GM, DAIMLER, VOLVO, SCANIA, AGCO
Segment manager František Trojek
30. 6. 2014 Page 9
Automotive
30. 6. 2014 INA SKALICA spol. s r.o. Page 10
Production program Segment 07 (G) Product line 04 Linear bearings Product line 08 Tensioning rollers Products RSH, RSEH, RSEMD,RSEMZ, RSEMB, RSEMC, RSEMZK, KB, KN, KS Main customers HONDA, TOYOTA, VW, SEAT, ŠKODA, AUDI, RENAULT, VOLVO, PSA, BMW, GM, PORSCHE, DAIMLER
Segment manager Peter Pekárek
30. 6. 2014 Page 10
Automotive
30. 6. 2014 INA SKALICA spol. s r.o. Page 11
Production program Segment 08 (H) Product line 09 Welded cages, cut out cages Products KZK, K, RNA, NK Main customers ZF, DAIMLER, HYUNDAI, VW, GETRAG, SCANIA, VOLVO, STIHL
Segment manager Petr Buček
30. 6. 2014 Page 11
Industrial
30. 6. 2014 INA SKALICA spol. s r.o. Page 12
Production program Segment 09 (I) Product line 25 Gear shift units Product line 27 Synchronizer rings for gearboxes Products Gear shift units, clamping fixtures, seat height adjusters, KLV, SYRZ, SYRI Main customers VW, GETRAG, GM – OPEL, DAIMLER, FIAT, AUDI, ZF LS
Segment manager Mário Vach
30. 6. 2014 Page 12
Automotive
30. 6. 2014 INA SKALICA spol. s r.o. Page 13
Production program Segment 10 (J)
Product line 12
Cylindrical rolling
bearing supports
Products
RN, RNN, HUTR, NUTR, KI,
RNU, NUP, NU, NJ, ZL,
SL01, SL04, SL18, SL19
Main customers
BOSCH, LIEBHERR,
JOHN DEER, STILL,
JUNGHEINRICH, JCB,
VOLVO, VW , ZF, GFT
Segment manager Roman Kudláč
30. 6. 2014 Page 13
Industrial
30. 6. 2014 INA SKALICA spol. s r.o. Page 14
Production program Segment 13 (M)
Product line 27
Synchronization
Products
SYRZ, SYRI
Main customers
GETRAG-FORD
PSA, VW, RENAULT, FIAT
Segment manager Martin Látal
30. 6. 2014 Page 14
Automotive
30. 6. 2014 INA SKALICA spol. s r.o. Page 15
Production program Segment 14 (N)
Product line 43
Release bearings
Products
ARL
Main customers
LuK, GETRAG, VW, FORD,
FTE, HONDA, FIAT, BMW
Segment manager Marián Vach
30. 6. 2014 Page 15
Automotive
30. 6. 2014 INA SKALICA spol. s r.o. Page 16
Production program Segment 15 (O)
Product line 28
Industrial applications
Products
Sensor bottom bracket bearing
BBRTS
Main customers
BOSCH
30. 6. 2014 Page 16
Industrial Segment manager Mário Vach
30. 6. 2014 INA SKALICA spol. s r.o. Page 17
Production program Segment 16 (P)
Product line 11
Needle bearings
Product line 21
Universal joint bearings
Products
HK1, BK, BU
WLT: RK, H, B, DKA
Main customers
BOSCH, CONTINENTAL,
BMW, HELLA,
THYSSEN KRUPP,
VALEO, WILLY ELBE, ZF LS,
IFA ROTORION –
POWERTRAIN GmbH
Segment manager Pavol Majkut
30. 6. 2014 Page 17
Industrial
30. 6. 2014 Strana 20
Production range MU1 - Segment 02 Product line 14 Ball bearings and radial insert ball bearings Products Radial insert ball bearings and housed bearing units Main customers John Deere, Class, CNH, Krones AG, VanDerLande, Brammer, Haluk, Werthenbach
Manager of Segment Martin Tuchyňa
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 21
Production range MU2 - Segment 03
Manager of Segment Ľuboslav Ďurica
Product line 14 Ball bearings and radial insert ball bearings Products 61800, 61900, 3800, 3900 Main customers LUK, Mercedes, SKF
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 22
Production range MU2 - Segment 05
Manager of Segment Martin Ormis
Product line 08 Idler pulley units Products Radial ball bearings with injection-moulded plastic belt pulley or metal belt pulley pressed-on, or other pressed-on clamping elements according to customer's requirements Main customers VW, PSA, Renault, AUDI, Daimler, GM, Ford, Volvo
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 24
Production range MU1 - Segment 07
Manager of Segment Slavomír Fecman
Product line 12 Cylindrical roller bearings Products HULR, KTRK, HMTR, LRQ (Lift mast rollers) Main customers Jungheinrich, Linde, Still
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 25
Production range MU3 - Segment 08
Manager of Segment Peter Čižmárik
Product line 33 Wheel bearings Products Wheel bearings of 3rd generation Main customers BMW, ZF, VW, AUDI, Daimler, Ford
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 27
Production range MU3 - Segment 10
Manager of Segment Daniel Pecko
Product line 33 Wheel bearings Products Components for (OR, FL) for wheel bearings of 2nd and 3rd generations Main customers BMW, ZF, VW, AUDI, Volvo, Ford, GM / Opel, Daimler
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 28
Production range MU3 - Segment 12
Manager of Segment Miloš Mizera
Forge Products Forgings for components for wheel bearings of 1st, 2nd and 3rd generations
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 30
Production range MU1 - Segment 15
Manager of Project František Bakoš
Product line 14 Ball bearings and radial insert ball bearings Products Tandem-Angular contact ball bearings Main customers BMW, ZF, Magna, Daimler
INA Kysuce, spol. s r.o.
30. 6. 2014 Page 31
Production range MU4 - Segment 16
Manager of Segment Gabriel Michalec
Product line 55 KGT – Ball nut assembly Products Parking brake Ball nut assembly Main customers Audi, TKPS, TRW, Volvo
INA Kysuce, spol. s r.o.
30. 6. 2014 INA SKALICA spol. s r.o.
TOP customers of INA SKALICA and INA Kysuce
14.5.2014
TOP customers of INA SKALICA and INA Kysuce
Best in Class
TOP customers of INA SKALICA and INA Kysuce
35
Next Projects KGT Lenkung RCEPS Porsche Volumen 120.000/Year Mando GMI700 – SUV Volumen 250.000/Year Hyundai TRW Volumen 280.000/Year
Tesla Model S – new design SOP Q2/2014 Volumen 160.000/Year
Tesla Model X – new design SOP Q1/2015 Volumen 250.000/Year
Mando GMxx – new design SOP Q2/2014 Volumen 320.000/Year
TOP customers of INA SKALICA and INA Kysuce
Page 36
Replacement of tapered roller bearings by angular contact ball bearings
Comparison of bearing friction torque
0,00
0,50
1,00
1,50
2,00
2,50
2 3 4 5 6 7 8 9 10
axial load [kN]
fric
tio
n t
orq
ue
[N
m]
TBB FAG F-239495TRB low frictionTRB standard
Standard Tapered roller bearing
Low friction Tapered roller bearing
Tandem ball bearing FAG F-239495
SWOT analysis for each FfQ Axiom
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SWOT analysis for each FfQ Axiom
14.5.2014
A hundred point FfQ action plan
Massnahmen Fit for Quality
Time-schedule for establishing FFQ Academy
One hundred-point FfQ action plan
14.5.2014
100 %
1. Quarter 2. Quarter 3. Quarter 4. Quarter January February March April May June July August September October November December
1. Team nomination
2. Team training
3. Determine the training concept
4. Determine the training content
5. Technical equipment
100%
100 %
100 %
100 %
100% Training room
Training equipment 100 %
100 %
100 %
6. Test of training (Feedback and optimalization)
7. Training schedule
8. Run the trainings
Fit for Quality Academy Roll-out in IWK 2012
14.5.2014
Costs: 20.000€ 14x Working tables, 2x Poka-Yoke, 2x Press, Parts for two assembly lines, 2x Scales,...
The costs were released from Mr.Patka and Mr.Suess in April 2012.
First visualisation – Assembly room
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14.5.2014
Daily: 18 participants and 2 trainers 8 teoretical blocks 10 practical excercises 2 assembly simulations
Duration: 8:00 – 16:00, 8 hours
First visualisation – Training room
A short video from Schaeffler TV:
14.5.2014
Number of trained employees: 2012 (2.10.2012 – 31.12.2012) – 382 persons 2013 (1.1.2013 – 31.12.2013) – 2816 persons* 2014 (1.1.2014 – 30.4.2014) – 1408 persons *(including participants from China, Hungary and Romania)
Fit for Quality Academy training
Fit for Quality Academy in INA Kysuce plant
14.5.2014
Fit for Quality Academy in INA Kysuce plant
14.5.2014
Who can not affect the quality of the product in our company ? Axiom 1 – Quality is everyone's responsibility
Development
Construction
Logistic
Material
Production
Control
Packing and storing
Sale Service
Marketing
The importance of SWOT analysis and the possibilities of its use
Axiom 2 – SWOT in every workplace
Development
Construction
Logistic
Material
Production
Control
Packing and storing
Sale
Service
Marketing
TO PREVENT SENDING A WRONG PARTS TO A CUSTOMER!
What is the purpose of a Near Miss analysis program?
How the program was born? - Near Miss program comes from facilities of Schaeffler North America
- The main objective was to reduce the number of customer´s complaints
- As result : reduction of claims in 2009 by 22%
Axiom 3 – Near Miss Analysis
The importance of layered audit Axiom 4 – Layered audit
Examples of some findings from audits: Bad / weak ergonomy of a workplace Overloaded boxes in a production Lost or wandered parts
Permanent education is an expensive investment for a company. This investment is necessary because only well trained employees are capable to perform high quality work continuously.
Try to think how the range of products produced by our company has changed over the past few years. Are we producing more simple or more complex products over the years?
Why is high qualification of employees important in our company?
Axiom 5 – Permanent training, high qualification of employees
Axiom 6 goal: - To understand the life-cycle and the importance of a Quality in it.
PEP = Produkt Entstehnung Prozess – The process of a product creation.
RLA = Risk Level Assesment – The assessment of a project risk level.
FMEA = Failure Mode Effect Analysis – Analysis of possible failure and the consequences.
Axiom 6 – Thorough Use of Existing tools
F-580224.02 YD: 180.000 in 2015
Daily, about 80,000 commercial airplanes take off all over the world. How many of them would crash on daily basis if their processes would be assured on:
95 % - 99 % -
99,99 % -
4000 daily 800 daily 8 daily
100% processes are therefore essential to achieve our "zero defect" goal
Why exactly 100% processes?
Axiom 7 – 100% process ensuring, 100% sure processes
Example from our simulation
Axiom 8 – Lessons learned
Name: Jig for screw tightening Area: Assembly Centre: Fit for Quality Academy
Axiom 8 – Examples
Before After
Tightening the screw was not ergonomic and not precise.
Installation of special jig, for tightening the screws on the working table.
The tightening is now ergonomic and precise.
Problem Solution Result
Number of the example: 0076 Author: Assembly Realization: KW48
Fit for Quality Academies Worlwide
Schaeffler Romania Schaeffler India Schaeffler China
14.5.2014
Roll-out Plan in Schaeffler World
14.5.2014
Fit for Quality Academy Schaeffler Romania, Brasov
14.5.2014
Fit for Quality Academy Schaeffler India, Pune
14.5.2014
Fit for Quality Academy Schaeffler China, Taicang
14.5.2014
Thank you for your attention!