ic general presentation ed8 2803 · general presentation customers ic maintains long term...

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




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



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


PRESENCE

Finished components, vehicles & engines

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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



PRESENCE

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE

¾ NEW ACTIVITIES



SERVICES & CAPABILITIES – LINE TOOLING (1/3)INTEGRALE CONSULTING


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





PRESENCE

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE


Vehicle nominal back

Platforms





PRESENCE

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE


Welding pallets Box side

Welding tools body side

Robotic Islands



SERVICES & CAPABILITIES – ENGINEERING OUTSOURCINGINTEGRALE CONSULTING


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• …



SERVICES & CAPABILITIES – TRUE LEAN MANUFACTURING IMPL.INTEGRALE CONSULTING


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



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



PRESENCE

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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.



PRESENCE

CLEVELAND

INDEX

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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


PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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


WHY INTEGRALE?INDEX



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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.



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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.



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE

Plan Do

CheckAct



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



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE




PISTON RINGS INSPECTION







PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE










PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



IC’s ASSETS - TRACEABILITY

SAMPLE OF DUMPER PULLEY’S REPLACEMENT TRACEABILITY SHEET

NOISE AUDIO RECORDING EXAMPLE (click on the image and play)



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



IC’s ASSETS - TRACEABILITY

SAMPLE OF BALANCESHAFT RUST INSPECTION’S TRACEABILITY SHEET



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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.



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



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


CARLOS MICÓAutomatisms & Machine Vision Engineer(+34) 619 583 422 – [email protected].



PRESENCE

CUSTOMERS

WHY INTEGRALE?

ADVANTAGES

TASK FORCE

IC’s ASSETS

PROGRAM LAUNCHING

MAIN CONTACTS

WORLWIDE EXPERIENCE



“Thank you for your kind attention”


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



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.


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.



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.


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.



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.


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



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.


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.


1/2



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.


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



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.


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.


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



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



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.



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.


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.




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.


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.



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).


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.



PROJECT

RESULTS & BENEFITS

HALFSHAFTS BEARINGS INSPECTION

• 200 vehicles salvaged.

• PROBLEM DESCRIPTION: 400 half shafts are suspect due to possible bearings cracking.


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.



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.


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



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.


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.



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.


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.

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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



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.


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.



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

ic general presentation ed8 2803 · general presentation customers ic maintains long term...

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