1. Salone d‘ Impresa - Venezia 18.05.2012
The Bosch approach to Process Management
Diesel Systems / Chassis Systems Control
1 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

2. Salone d‘ Impresa - Venezia 18.05.2012
BarP Process Model:
Management Processes
Change
Strategic Management
Management
Core Processes (Value Adding Processes)
Product Engineering Process
Product (PEP)
Development Production Engineering
Customer
Customer
Order Fulfillment Process
Procurement Production Delivery
Support Processes
Human Quality Health Safety IT Coordination
Controlling Technical Plant Protection
Resources Purchasing Management and and
and Finance Functions and Security
Management and Methods Environment Organisation
Diesel Systems / Chassis Systems Control
2 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

3. Salone d‘ Impresa - Venezia 18.05.2012
Order Fulfillment Process:
BPS approach
Diesel Systems / Chassis Systems Control
3 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

4. Salone d‘ Impresa - Venezia 18.05.2012
The Bosch Production System:
Targets
” True North”
Best In Class
Initial Ideal
State Principles
Eight general rules, that status
describe the BPS philosophy
• 0 failure
Tools • One Piece Flow
Empowerment in order to • in sequence
execute the principles • according to
demand
• 100% added value
BPS our success for Lean Production
Diesel Systems / Chassis Systems Control
4 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

5. Salone d‘ Impresa - Venezia 18.05.2012
The Bosch Production System:
BPS Principles Perfect Quality Process Orientation
as Guide Line
Flexibility Pull System
BPS Elements
for Value Stream Quick Change Q- Poka Kaizen-
empowering Design Over Tools Yoke Workshop
Consumption Ship to
TPM Lean Line Design 6S
Control Line
Point Flow Oriented Cyclical
Lay Out Leveling ...
CIP Material Flow
Diesel Systems / Chassis Systems Control
5 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

6. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
6 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

7. Salone d‘ Impresa - Venezia 18.05.2012
Since 2006: Pull System through TPM
- TPM/5S
Perfect Quality Process Orientation
Definierte ä ne Visualisation
Flexibility Pull System
Value Stream Quick Change Q- Poka Kaizen-
Design Over Tools Yoke Workshop
Consumption Ship to
TPM Lean Line Design 6S
Control Line Gemeinsame
Point Flow Oriented Cyclical
Lay Out Leveling ... Aufr ä
CIP Material Flow
Aktionen an
Wochenenden
TPM
TPM to stabilize the OEE of all bottleneck processes
Diesel Systems / Chassis Systems Control
7 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

8. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
8 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

9. Salone d‘ Impresa - Venezia 18.05.2012
Since 2007: Flexibility through Material Flow
Batch size for transport = 1600 Batch size for transport = 120
Perfect Quality Process Orientation
Flexibility Pull System
Value Stream Quick Change Q- Poka Kaizen-
Design Over Tools Yoke Workshop
Consumption Ship to
TPM Lean Line Design 6S
Control Line
Point Flow Oriented Cyclical
Lay Out Leveling ...
CIP Material Flow
Cyclical Material
Flow
Frequency transportation allows continuous stock reduction
Diesel Systems / Chassis Systems Control
9 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

10. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
10 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

11. Salone d‘ Impresa - Venezia 18.05.2012
Since 2008: Transparency through
5S + Safety = 6S
Perfect Quality Process Orientation
Flexibility Pull System
Value Stream Quick Change Q- Poka Kaizen-
Design Over Tools Yoke Workshop
Consumption Ship to
TPM Lean Line Design 6S
Control Line
Point Flow Oriented Cyclical
Lay Out Leveling ...
CIP Material Flow
6S
6S as must for BPS
Diesel Systems / Chassis Systems Control
11 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

12. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
12 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

13. Salone d‘ Impresa - Venezia 18.05.2012
Since 2009: Associate Involvement - empowering
the entire organization
 Training for
Managers
Training Top Down
 Shopfloor PM  Shopfloor
Training Bottom Up
Management VSMgr
Management
Cycle Cycle
Department
 Leveling and Manager  Standards for
Pull TeCo and
Groupleader
Tele
 Training for Teamkoordinater, Planer,
Planer Teamleader  Standards at
Shopfloor for
Workers
workers
Training, involvement and motivation as success factor
Diesel Systems / Chassis Systems Control
13 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

14. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
14 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

15. Salone d‘ Impresa - Venezia 18.05.2012
Since 2009: Associate Involvement
Management as Mentor in daily work
Targ
et
Management Top Down:
- Development of the Vision
- Mentor - Mentee
- Support employees to
Management Bottom Up:
find solutions
- Release of resources
- Target setting
Management
Associate
I Know it I do it I Lead it I teach it
Diesel Systems / Chassis Systems Control
15 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

16. Salone d‘ Impresa - Venezia 18.05.2012
BarP BPS success story:
From System
Leaders CIP to
Training as Point CIP
program for Mentor
• Lean Admin
Reinforce all leaders Review
5S and workers Training on • Training
Cyclical shop floor:
blue collar:
System CIP
Material Training on • Planners
• Quick
to Point
shop floor: CIP,
Flow • Pull-system • Working Change Leveling
TPM stabilisation According Over
• System CIP
• Ship to Line to Standard
• VSD Vision to Point
roll-out • Shop-floor
• CIP in al CIP
• Reinforce Manage-
• Integration direct areas
bottom-up ment Cycle
BPS-CIP • Cyclical
Material processes
• CIP on
shop floor Flow
• Linea
Gialla
2006 2007 2008 2009 2010 2011
Diesel Systems / Chassis Systems Control
16 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

17. Salone d‘ Impresa - Venezia 18.05.2012
Since 2010: Continous Improvement through
„From System CIP to Point CIP“
 4 System CIP Workshops per year
 Duration 2 days
 Participants:
 PM (PT, PC), VSMgrs
 Department Managers, Group Leaders, Planners
 First line shop floor manager (Foremen)
 External Fresh Eye
 Content of the System CIP LIVE Workshop:
 Customer Requirements 30’ Plenum
 Business Requirements, current/target state 30’ VSMgrs
 “Go to Gemba”LIVE, VSM/Bubble Diagram 180’ 7 Workgroups
 Development VSD/Bubble Diagram 180’ 7 Workgroups
 Definition of projects including KPIs and Tree 120’ 7 Workgroups
 Roadmap 180’ 7 Workgroups
 Release of projects by PM (PT,PC), VSMgrs 90’ Plenum
Leaders drive with Speed the Improvement Process
Diesel Systems / Chassis Systems Control
17 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

18. Salone d‘ Impresa - Venezia 18.05.2012
Positive experience:
 A Production System is a change of mindset:
 If you decide to do it, no doubt
 JUST DO IT
 The Production System isn‘t a Sprint, it is a Marathon
 Leaders: I can lead it
 Involve the whole organization
 Start consequently with 6S
 No Production System without 6S
 Deployment and Training through the entire organization
Diesel Systems / Chassis Systems Control
18 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

19. Salone d‘ Impresa - Venezia 18.05.2012
Support Processes:
Lean Administration approach
Diesel Systems / Chassis Systems Control
19 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

20. Salone d‘ Impresa - Venezia 18.05.2012
BarP Lean Administration – VS visualization:
 Flusso di informazioni
VSM = modello “swimlanes”
Diesel Systems / Chassis Systems Control
20 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

21. Salone d‘ Impresa - Venezia 18.05.2012
BarP Lean Administration: High
maturity
level
CIP
Redefined running • Improvement
process
approach • Point CIP at managed at
VSDiA office 100% lowest level
Process • Organization
• Strategy
installed
• Competence
(employees,
planers)
mapping • Vision level 4 for • higher level
Roll-out • Training for
Lean
• WS
• Training
managers assures a role
of mentor
• Training for referents
Lean • Redesign
• Lean experts of several
Administrati • All the main key
on starts processes processes
• Basic are (VSD)
training for mapped
managers (VSM)
2009 2010 2011 2012 2013 2014
Diesel Systems / Chassis Systems Control
21 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

22. Salone d‘ Impresa - Venezia 18.05.2012
Since 2012 – Redefined approach:
 Revised strategy and long term vision
 New department fully dedicated to Lean Administration
 Structured VSDiA projects to assure :
 Reasonable duration (4 to 8 months)
 Adequate and stable results
Put the basis for Lean Administration success story
Diesel Systems / Chassis Systems Control
22 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.

23. Salone d‘ Impresa - Venezia 18.05.2012
BarP Lean Administration: High
maturity
level
CIP
Redefined running • Improvement
process
approach • Point CIP at managed at
VSDiA office 100% lowest level
Process • Organization
• Strategy
installed
• Competence
(employees,
planers)
mapping • Training for
• Vision level 4 for • higher level
• WS managers assures a role
Roll-out Lean
referents
• Training of mentor
• Training for
Lean • Redesign
experts of several
• Lean
• All the main key
Administrati
processes processes
on starts
are (VSD)
• Basic
training for mapped
managers (VSM)
2009 2010 2011 2012 2013 2014
Diesel Systems / Chassis Systems Control
23 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.