Delphi Product and Service Solution - apra- · PDF file– Sensor Fusion Driver State Alerts ... Oxygen & Battery IVT Sensors ... Delphi has remanufactured products for over 25 years

Delphi Confidential 1

Delphi Product and Service Solution

Bharat M FataniaGlobal Remanufacturing Manger


� Delphi Overview

� DPSS Remanufacturing

� DDA Remanufacturing


Overview of Delphi Corporation

Innovation for the Real World


Globally Supporting Our Customers

�Leading global supplier of mobile electronics and transportationsystems for original equipment and the aftermarket, including powertrain, safety, thermal, controls & security systems, electrical/electronic architecture and in-car entertainment and communication technologies

– Ranked 121 on the 2009 U.S. Fortune 500

�Vision - Be Recognized By Our Customers As Their Best Supplier!

�Recognized for operational execution with a global manufacturingfootprint - strategically located to support our customers

�Advanced technology and original equipment (OE) quality parts and service

– Automotive, aftermarket and original equipment service– Computing, communications and energy applications

Delphi Confidential 5As of 9/2010

Diverse and Global, Responsive to Customer and Market Needs

Employment:Countries:

Customers:

Employment:Countries:

Customers:

101,0003012,400 (including aftermarket)

101,0003012,400 (including aftermarket)


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Driving Global Innovation-In Close Collaboration with Our Customers

Bascharage, Lux.

Juarez, Mexico Shanghai, China

Detroit, USA

Key Global Technical Centers

São Paulo, Brazil

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Krakow, Poland

Bangalore, India

14 Technical Centers � 10 Countries � 16,000 Scientists & Engineers


Diverse Customer Base Drives Growth

No single customer accounts for more than 20% of global sales


Core Innovations = Future PossibilitiesCore Automotive Markets Adjacent Markets

Military/Aerospace

Residential/Commercial Heating and Cooling

Electrical/ElectronicArchitecture

Electronics & Safety

Powertrain Systems

Thermal Systems

Commercial Vehicles

Aftermarket


Committed to the Kind of Innovation that Will Keep Our Planet Green and Its Occupants Safer and More Connected

MEGATRENDSMEGATRENDS� People Megatrends

– Natural Growth

– People Live Longer

– Generations X & Y

– Increased Concern about Safety, Security and Privacy

– Health Care

– 8/5 > 12/6 > 24/7

� World Megatrends– World Turmoil

– Globalization

– Higher Cost of Natural Resources

– Increasing Environmental Awareness/ Regulations

� Technological Megatrends– Information Explosion

– Wireless World

�Safe – Traffic congestion in

major metro areas around the world becomes worse; more accidents; longer commute; higher stress level

�Green– Fast growing

economies: more fuel for mobile platforms

– Demand for electrical energy and related conventional resources far exceeds current capabilities

�Connected– Global demand for

broadband access will continue to grow


Portfolio of Enhanced Safety Solutions

�Active Safety Systems

– Front, Rear and Side Detection

– Radar and Vision Sensing

– Sensor Fusion

�Driver State Alerts– Fatigue/Drowsiness– Distraction

�Safety Electronics– Airbag Control Units– Pressure,

Acceleration, Combination, Rollover, and Pedestrian Sensors

�Occupant Classification Systems

– Full and Infant-only Suppression

– Seat Belt Reminder

�Battery Disconnects�Battery Monitoring

Device�HMI (Human Machine

Interface)– Diagnostics– Control Modules and Units– Haptic Devices


Portfolio of Green Solutions� Fuel Economy and Performance

Technologies

– Cylinder Deactivation System

– Two-step Valve Train with Dual Independent Cam Phasers

– Brushless Fuel Pump Modules

� Alternative Fuel Systems/Components

– Fuel System for Dimethyl Ether

� Evaporative Emissions Canisters

� Diesel Fuel Injection Systems and After-treatment

� Gasoline Direct Injection

� Next Generation Energy Efficient A/C

� HVAC Compressors

� HVAC Systems for Alternative Refrigerants

� Diagnostic Systems

� Electric HVAC Systems

� Hybrid and Electric Vehicle Technologies

� Power Conversion Products

� High Voltage Battery Pack System

� Ammonia, Planar Oxygen & Battery IVT Sensors

� Electronics Packaging

� Halogen-free Cable

� Aluminum Cable

� Miniaturization

� Navigation

� Ultra Light Radio


Portfolio of Connectivity Solutions

� Connected Vehicle

– In-vehicle Communications and Entertainment

– 3G/WiMax, WiFi, DSRC

� Vehicle Infrastructure Interface (VII) and Vehicle-to-Vehicle Interface

� Satellite Audio, Video and Data Systems

� Digital Receivers

� Advanced Reception Systems

� Navigation Systems

� Portable Device Interfaces

� Wireless Connectivity

� Security Systems

� Aftermarket Telematics

� Data Connectivity - USB Consumer Port

� HMI (Human Machine Interface)

– Diagnostics

– Control Modules and Units

– Haptic Devices

– Displays

� Commercial Aviation and Electronics

� High-density, High-speed Interconnects

� Controls


New Delphi: Market-Driven Product Lines, Segmented into Five Divisions

Electrical/Electronic Architecture- Electrical/Electronic Distribution Systems- Connection Systems

Electronics & Safety- Electronic Controls- Infotainment & Driver Interface

Powertrain Systems- Gasoline Engine Management Systems- Diesel Engine Management Systems

Thermal Systems- Thermal Automotive- Thermal Residential and Commercial Heat Exchangers

Product & Service Solutions- Diesel- Independent Aftermarket- Original Equipment Service


RemanufacturingDPSS


Delphi’s Commitment to Remanufacturing

�Delphi has remanufactured products for over 25 years

�Remanufacture many mechanical and electrical products in categories including powertrain, audio / instrumentation and chassis / security

�Remanufacturing is key to Delphi’s manufacturing strategy– Provides manufacturing capability for a long product life cycle

» 10-15 year customer OES service parts requirements

– SIGNIFICANT REDUCTION OF LIFE TIME BUY INVENTORIES

– Provides our OE customer a lower cost alternative

– Critical for higher technology electrical products


Tokyo, Japan

Sao Paulo, Brazil

Viersen, Germany

UK – 4 Locations

Buenos Aires, Argentina

Seoul, S. Korea

Whitby, Ontario

Montreal-Nord, Quebec

Richmond Hill, Ontario

Calgary, Alberta

Mexico City

DubiaUAE

Luzerne, Switzerland

US – 9 Locations

Nuremberg, Germany

Remanufacturing Centers

Suzhou, China

Barcelona, Spain

Blois, France

29 Total Reman Centers


RemanufacturingDDA


Market Segments by engine sizeMarket Segments by engine size

2

1,5

1

0,5

1 2 3 6 9 12

Pass CarLD Commercial

(50-350 hp)

US Light Truck(80-250 hp)

Medium DutyOn and Off Highway

(40-350 hp)

Heavy Duty Segment(215-600 hp)

CylinderCapacity(Litre/Cyl)

Small EngineApplications(10-60 hp)

EngineCapacity(Litre)Non linear


DelphiDelphi’’s Product Coverages Product Coverage

Heavy Duty Common Rail

Light Duty Rotary SystemsLight Duty Common RailSolenoid Direct Piezo

Heavy Duty Electronic Unit InjectorElectronic Unit Pump

Small Applications Cassette PumpsUPCRS

Medium Duty On/Off Highway

Rotary PumpsMD Common Rail Elect. & Mech. Unit Injector

Mechanical Injectors


Global Diesel Market

Global Diesel Vehicle Parc

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

par

c m

illions

Car/LCVs Trucks Agricultural Other

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W.EUROPEAN LIGHT DUTY VEHICLE SALESVolumes in bar% diesel in line

0

3

6

9

12

15

18

90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

(millions)

DIESELVOLUMES

% DIESEL


��WORDLWIDE LIGHT DUTY VEHICLE SALES

Volumes in bar% diesel in line

0

10

20

30

40

50

60

70

80

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

(millions)

DIESELVOLUMES

% DIESEL


Technology TrendsTechnology Trends

Emissions legislation drives the future technologies

• IDI

• Rotary Pump

• IDI & DI

• Rotary Pump

• EUI or CR

• DI Rotary

• EUI or CR

• EGR

• Diesel Oxi-cat

• EUI or CR

• EGR

• VGT

• Intercooled turbo

• Diesel Oxi-Cat

• DPF

• CR

• EUI (HD only)

• EGR

• VGT

• VVT


• Diesel Oxi-Cat

• DPF (100%)

• NOx trap or SCR (?)

• Low sulphur fuel

• CR – advanced

• EUI (HD only)

• In Cyl: pressure control

• EGR

• VGT

• VVT


• Diesel Oxi-Cat

• DPF (100%)

• NOx trap or SCR

• Advanced combustion (HCCI?)

• Low sulphur fuel

Increasing Technology Content &

EMS Integration

(EC93) (EC96)

NOx+HC

PM

g/km

“ZERO” EMISSIONS

00.5

11.5

Euro1 Euro2 Euro3 Euro4 Euro5 Euro6 tbc


Remanufacturing Locations

Troy, Michigan

Gillingham, England

Blois, FranceSudbury, England

Barcelona, Spain


What is Remanufacturing?

� “Remanufacturing is recycling by manufacturing “good as new” product from used products.” 1

�Overall Benefits to Remanufacturing– Substantial material reuse (approximately 50 to 70%)

– Substantial energy savings (approximately 85% or more is typical)

– Less impact on environment (landfills, waste, processing)

�Types of Automotive Remanufacturing– Hard arts remanufacturing (Alternators, steering, brake calipers)

» Disassemble, clean, inspect, re-qualify parts, reassemble, test, pack

– Electronics remanufacturing (radios, engine control modules)

» Test, clean, repair, retest, pack

1 Remanufacturing The Ultimate Form of Recycling by Rolf Steinhilper, Fraunhofer IRB Verlag, 2008


Difference between remanufacturing and other elements of ‘RE’

� Remanufacturing is not…

• Re-use: Generally applies to a product that has been used previously. The product will retain the problems it acquired during its previous life.

• Recycle: Returns a product to raw material state, which can be reprocessed back into raw material for a future manufacturing process. It destroys the value added to the raw material.

• Refurbish/Recondition: Restore a product’s functionally but the process may not disassemble and clean all of a product’s components.

• Repair: Makes a broken product operational again. Root cause analysis ofthe problem is generally not performed in the repair process which means the product may not perform like a new product


• Distinction in terms of process

Difference between remanufacturing and other elements of ‘re’

Remanufacturing Repair

Used or Defective Parts Defective parts

Industrialised process Mechanic's work

Root cause analysis Failure detection

Overall restoration to like new condition Individual repair of defect

Upgrading of parts Product retains earlier standard

Customer receives anonymous product Customer keeps his/her own product

Like-new or lifetime warranty Warranty covering repair work only

Remanufacturing is not a widely understood concept

Ron Giuntini, The Remanufacturing Institute, 2006


• Distinction in terms of positioning within the material flows loop.

Difference between remanufacturing and other elements of ‘RE’

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Remanufacturing Process Flow


Summary

To offer Customers remanufactured programmes which deliver:

– Product remanufactured (not repaired) in the Original Equipment facilities to deliver:

» Quality consistent with O.E.

» Remanufactured to the latest specifications

– A cost effective solution, delivering:

» An cost benefit relative to the new unit

» A cost effective solution throughout the lifetime of the vehicle, and when the system is ‘non current’ O.E.


� All programmes are delivered to an jointly agreed remanufacturing specification

� Components are inspected and if required replaced with new to the latest design

� Each programme has processes mapped out to meet exacting OE standards and requirements

� Assembly / sub processes and testing follow OE requirements

Remanufacturing Specifications


When is the Right Time for remanufacturing?

�While in OE Production?– Delphi utilizes in-warranty testing & remanufacturing with many customer

programs

�Just as OE Production Ends?– Reduction of life time builds

– Can be a lower cost solution, vs significant price increases due to higher costs (low volume pricing, supply issues, MOQ issues)

�Later in the Past Model Service Life?– Reduction of life time builds

– Can be a lower cost solution, vs significant price increases due to higher costs (low volume pricing, supply issues, MOQ issues)


Remanufacturing Obstacles & Constraints

Parts Availability

Assembly / Disassembly 25%

Design Simplicity 21%

Recoverability of Cores

Core Availability

Technical Specifications 7%

Market Demand

Permanent Fasteners

Size of Product

Testing Required

Price of Parts 4%

43%

What Makes A Product More Difficult To Remanufacture

4%

4%

4%

4%

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

18%

14%

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Technology: the Micron

Particle of Dust4 microns = 157 millionth’s inch

Particle of Cigarette Smoke2.5 microns= 98 millionth’s inch

One Tenth of One Thousand’s of an Inch2.5 microns = 100 millionth’s inch

THE MICRON1 micron = 39 millionth’s inch

Human Hair Size76 microns = 3 thousands inch

One Thousand’s of an Inch25 microns = 1 thousand’s inch


Real World Comparisons

Pressure Temperature Spray Speed

Accuracy

2500 Bar 250-350C 1500 MPH

Environment

Tolerance

Hair Dia=50�M

1 �MPlunger Clearance

Pilot

Main0.5 ms

Timing

0.5 msec0.2 Bee wing beats

Volume

1mm3

Pilot Injection


Translate OE to Reman


Engineering Capabilities

�DDA-Reman leverages Delphi’s global OE engineering expertise to support our remanufacturing efforts:

– Metallurgical Evaluation

– Dimensioning and Measurement

– Durability Evaluation

– Design Enhancement

– Value Engineering

– Balance investments Vs volumes


Reman Facilities


Reman Facilities

Incoming Inspection & Data Entry

Complaint & Failure Analysis

Final Test & QC Audit

Parts Replacement & Verification

Data Entry & Final Shipping


Lean Enterprise

�DDA-Reman continues to transform itself into a lean organization through continuous improvement initiatives and adherence to Delphi’s 5 lean Principles:

– Right Parts, Right Time

– Short Lead-time

– Built-in Quality

– High Capacity Utilization

– High Resource Utilization

�Our goal is to be recognized by our customers as their best supplier!


Remanufacturing concept & significance

� Cost savings whilst maintaining the highest quality standards

• Remanufacturing process saves up to 80% of the energy and material it would take to manufacture news parts.• Remanufactured parts are typically 30 – 50% below the cost of new parts• Remanufactured parts are priced 60 – 80% of new parts

� Environmental compliance• Reduce waste – Material conservation• Energy conservation• Reduce emissions (castings are not resmelt)

� Customer service improvements• Service Parts availability• Product upgrades• Lower cost service parts for older vehicles & emerging economies• New markets development opportunities• A positive, socially concerned image

Remanufacturing is Good for Society, Good for Business, and Good for the Environment


Thank you

Documents

Delphi Product and Service Solution - apra- · PDF file– Sensor Fusion Driver State Alerts ... Oxygen & Battery IVT Sensors ... Delphi has remanufactured products for over 25 years