The right part of the right quality in the right quantity at the right moment in the right place

Supplier

Customer

Presentation by : Jayaprakash Shetty (General Manager Technical, Bangalore Plant)

Division : BanP/PT 09.06

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Structure of the Bosch Production System

Customer Satisfaction and Business Success

Quality

Cost

Delivery

Process Orientation Perfect Quality

Pull System Flexibility and

Standardization Transparent Process CIP

Waste Elimination

Associate Involvement and Empowerment

Associate Satisfaction

Division : BanP/PT

09.06
F4G/P-BPS

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

BanP BPS Vision

BPS in BanP
1. Customer off-take determines our production. Our inventories are visualized in decentralized supermarkets to enable continuous reduction. 2. We re-lay our resources and change our organization for smooth flow of material and information in the value stream. The efficiency of the total value stream is measured and improved. 3. We reduce lot sizes across the supply chain by quick change over and flexible production practices. We produce & dispatch runners with increasing frequency. 4. Good housekeeping and visualization along with our TPM initiatives aid standardization and lead to quick response to deviations. 5. We standardize the work of our associates to enable balanced flow of parts. We encourage teams working consistently for improvement.
Testing

Be the benchmark for BPS in Bosch

Daily

Bosch BanP

I
Internal Milkrun to the point of usage
I

I
Machining

Assembly

From Cells to Lean lines

6. We develop and rate our vendors on BPS metrics.

BPS Assessment > 600 points by 2008

Division BanP/PT 09.06 Division ::BanP/PM 27.03.06
This is the exclusive property of Motor Industries Co. Ltd. This is the exclusive property of Motor Industries Co. Ltd. Without their consent, may not be reproduced or given to third parties. Without their consent, ititmay not be reproduced or given to third parties.

BanP : Bosch Production System

We are Changing the way we work in our Plant

Target : EPEI of 1 day for runners in all products - Leveled production in all assembly lines - Quick change over projects

Target: Reduction of Total Inventory in the supply chain

Daily

Supplier

Every 2 hours Inspection

Super market

- Plant wide milk runs : External and internal - Frequent supply of material in smaller batches - Move from centralized LOG to decentralized super markets - Frequent ordering by sales and frequent dispatches

Receiving area

Division : BanP/PT

09.06

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

BanP Bosch Production System : Bosch Production System

We are Changing the way we work in our Plant

Focus on Value Stream Improvements

Total Productive Maintenance focussing on Bottleneck Machines

Shop layout changes for BPS (Cells) with Lean Line Design

Priority for improving Material flow and Associate movements

Improving First Pass Yield of all Processes Increased involvement of Associates for Improvements on the shop floor
Division : BanP/PT 09.06
This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

BanP : Bosch Production System

We need your support

What
Delivery of Runners at least Daily (Cyclic, Periodic and Consistent)

How
OEE* should be > 80% for all your critical machines Change Over time < 10 minutes in all your processes Multi-skilling of associates to combat Absenteeism

Ship to Line status for all Supplier Part no. combinations

First Pass Yield of > 90% across your value stream Poka-Yoke for all manual processes Process Capability index Cpk > 1.66 for all machines

* OEE : Overall Equipment Analysis = Availability x Quality Rate x Performance

Division : BanP/PT 09.06

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

BPS Our requirements

We need your support

What
Aim for one piece flow Manufacturing all Implement Material- flow oriented layout Milk-run with your suppliers Runners everyday and Quick Change Over of less than ten minutes in your processes reducing batch sizes Pull based Production Levelling Single Loop or Two Loop Pull system Internal Milk-run in your Plant Supermarkets for Components
09.06

How

Supply parts based on MICO consumption (Kanban system)

Division : BanP/PT

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

BPS Our requirements

We need your support

What How
Short lead times for procurement Short replenishment time of one day or less Many Internal Milk-runs in a day Restructure to accommodate one piece flow

Flexibility to accommodate changes of +/- 10% in weekly schedule within 24 hours

Work in two staggered shifts Lean line design (Chakku-Chakku)

Division : BanP/PT

09.06

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.

The right part of the right quality in the right quantity at the right moment in the right place

Lets do it Together !

Division : BanP/PT

09.06

This is the exclusive property of Motor Industries Co. Ltd. Without their consent, it may not be reproduced or given to third parties.