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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 aheadMariano CilentiDirector Manufacturing

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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

2

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.

RBITRobert 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 GmbHBranch in Italy

PEETIT ETAS GmbHBranch in Italy

SXIC (AA)Deca S.r.l.

BARI

MILANO

TORINO

BERGAMO

TREVISO

UDINE

CREMONA

BOLOGNA

ROMA

REGGIO E.


MODENA

BEIT (BEBS)Bosch Energy and Building Solutions Italy S.r.l.

2013Sales 1,8 mld. EUR19 legal entities5.848 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.

3

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


BOSCH Bari Plant

5

Bari & Bosch: a success story of technological evolution from Southern Italy


BOSCH Bari Plant

The birthplace of Common Rail

First car equipped with Bosch Common Rail in the early 1990’s

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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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Strong Focus on Operational Excellence

New products

QualityCost

Delivery

Sustained performance

Operational Excellence

1,16 1,21 1,21 1,271,35 1,39

1,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013

Productivity [pcs/h]

97 98 99100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013

On Time Delivery [%]

2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013

Inventory - TCT [Days]

2,211,66

0,820,42 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 1,271,35 1,39

1,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


97 98 99100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

1,16 1,21 1,21 1,271,35 1,39

1,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


97 98 99100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

1,16 1,21 1,21 1,271,35 1,39

1,5

1

1,2

1,4

1,6

2007 2008 2009 2010 2011 2012 2013


97 98 99100 100 100 100

90

95

100

2007 2008 2009 2010 2011 2012 2013


2833

2521 20 19 17

10

20

30

40

2007 2008 2009 2010 2011 2012 2013


2,211,66

0,820,42 0,36 0,30 0,25

0

1

2

3

2007 2008 2009 2010 2011 2012 2013


0

1

2

3

4

2007 2008 2009 2010 2011 2012 2013


BPS Award Winner

(Overall)

BPS Award Winner

(Deliver)

Quality Award 2010

EFQM Prize2012

BPS Awards

2011, 2013

BOSCH Bari Plant

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The Strategic Planning Circle

Strategy Review

Strategic Analysis

Strategy Developme

nt

Strategy Deployme

nt and Target

Definition

Target Deployme

nt

StrategicPlanning

Circle

• Stakeholder Analysis• Competitor Analysis

• SWOT Analysis

• Vision

• Business Plan• Balanced Scorecard

• Individual Targets

BOSCH Bari Plant

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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 partnerin society

Agile resource management

Continuous outperformance of targets

Marketing for newproducts and customers

Cost innovation forproducts and processes

Responsiveness tocustomer demands

Living Lean, improving fast

We challenge and deliver

BOSCH Bari Plant

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BarP Strategy & R2E














BOSCH Bari Plant

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BarP Strategy & R2E














BOSCH Bari Plant

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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 TeamPlant 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


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


Production

BOSCH Bari Plant

R2E led by Function Managers; teams built with no additional resources

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Corporate Social Responsibility: mutual benefits for Society and Bosch


BOSCH Bari Plant

Bari Plant Social CharterB

enefits

for

Bosc

h

Bari

Benefits

for

Soci

ety

Environment

Health & Safety

Waste Collectio

n

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 keyplayers’ support

CO2 reductionprojects

Sponsorships – Donations (Scolarships) Competen

ce

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BOSCH Bari Plant

Environment

Environmental activities and education

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VIDEO

Better working conditions, healthier lifestyle


BOSCH Bari Plant

Health & Safety

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Partnerships and cooperations with universities and schools


BOSCH Bari Plant

Competence

Introducing the dual education model in Southern Italy

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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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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.19

BOSCH Bari Plant

EEA Award


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

vv

Ranking in DS [%]

1 BarP 100

1 RBTR 100

1 RzP 100

2 FeP 99,84

3 VHIT 99,32

4 RBCB 99,21

5 LOG11 99,04

6 HlP 98,65

7 HoP1 98,16

8 J hP 97,95

9 BaP 84,96

10 ChP 0

YTD DS 97,61

Target 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 2012Mar Apr May Jun Jul Aug Sep Oct Nov Dec YTD

2013

%

1

22

3

10

2

1

Vv


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 21


BOSCH Bari Plant

Always one step ahead

22

sürdürülebilir bir gelecek yaratma, Çeviklikle yönetme, Çalışanların yetenekleriyle...

Presentations & Public Speaking