Les réseaux mondiaux d innovation dans l industrie automobile Un exemple : Delphi

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1 1 Les réseaux mondiaux d innovation dans l industrie automobile Un exemple : Delphi Rémi Kaiser Engineering & Quality director, Delphi Europe, Middle-East and Africa - President Delphi France Troisième conférence «Réseaux mondiaux d innovation» - Conférence ANRT/IFRI - 27 Avril 2006

2 Agenda Delphi Overview and History Delphi Strategy Delphi Organization & Global Presence 2

3 Delphi Heritage 3

4 Evolution of Delphi 1988 ACG Worldwide Group structure created 1994 ACG Worldwide established as separate business sector 1995 ACG Worldwide became Delphi Automotive Systems 1998 Delphi incorporated as a subsidiary 1999 February 5th - Delphi initial Public Offering : DPH on NYSE 1999 May 28th - Delphi becomes a totally independent company 2000 Acquisition of Delphi Diesel Systems from TRW/Lucas 2000: Acquisition of Automotive Products Distribution Services [AP Lockheed] 2001 Acquisition of Easton VS/ED (Delphi Mechatronic Systems) 2002 Delphi Automotive Systems becomes Delphi 2002 Delphi Aftermarket becomes Product & Service Solutions 2003 Acquisition of Grundig Car InterMedia Systems 2004 Acquisition of Dynamit Nobel AIS GmbH Automotive Ignition Systems; Acquisition by Delphi Medical Systems of Peak Industries (medical devices) 2005 Acquisition by Delphi Medical Systems of Caretools (advanced electronics medical record) 2005 Filing of Chapter 11 in US 4

5 Delphi Breadth of Product Dynamics, Propulsion, Thermal and Interior Air/Fuel Systems Braking Systems Chassis Systems and Modules Climate Control Systems HVAC Modules, Condensers Energy Storage and Conversion Engine Management Systems Exhaust After-treatment Systems Fuel Handling and Evaporative Systems Wheel Bearing Modules Quadrasteer Four-wheel Steering Half Shafts, CV Joints Powertrain Cooling Systems Radiators, Oil Coolers Sensors & Solenoids Valve Train Products Vehicle Control Systems Electric Power Steering, Steering Columns, Steering Gears, Driveline Systems Cockpits Instrument Panels Electrical, Electronics and Safety Airbag Systems Audio Systems Body and Security Electronics Chassis Electronics Communications Systems Connection Systems Driver Information and Controls Electronic Control Units Electrical/Electronic Centers Forewarn Collision Warning Systems Navigation Systems Powertrain Controllers Power and Signal Distribution Systems Restraint Systems Electronics Seat Belts Semiconductors Sensors and Power Modules Steering Wheels Switch Products 5 1dd05-8.0

6 We Are An Innovations Company Core Markets New Markets Diesel & Gas Engine Management Electrical Architecture Commercial Vehicles Marine Electronics, Switches & Sensors Consumer Electronics Computers / Peripherals Thermal Wireless Medical Devices Military / Homeland Security 6

7 2004 Sales 2004 Sales $28.6 B* Electrical, Electronics, & Safety Sector 2004 Sales $13.5 B Integrated Body Electronics Powertrain Electronics Chassis & Safety Electronics Audio Systems & Mobile Multimedia Safety Systems Electrical & Electronic Systems Product & Service Solutions Dynamics, Propulsion Thermal & Interior Sector 2004 Sales $13.26 B Engine & Emission Management Systems Energy Management Systems Vehicle Dynamics Thermal Management Systems Interiors Sales & Marketing Enterprise Technologies Lean Manufacturing Automotive Holdings Group 2004 Sales $ 1.86 B Generators Instrumentation Other 7 *Includes Inter-Sector eliminations of ($2.0B) Based on June, 2005 Restated Financial Statement

8 Extensive Global Presence U.S. & Canada Manufacturing sites: Employment: Joint ventures: Technical centers: 45 50, Europe & Middle East Manufacturing sites: 61 Employment: 49,000 Joint ventures: 9 Technical centers: 10 Total Delphi Manufacturing sites: Employment: Joint ventures: Technical centers: , Mexico & South America Manufacturing sites: 47 Employment: 75,000 Joint ventures: 9 Technical centers: 4 Asia Pacific Manufacturing sites: 14 Employment: 10,000 Joint ventures: 17 Technical centers: 6 8 As of 3/31/05

9 Diversified Customer Breadth 9

10 Footprint optimization : Main drivers Advanced Products Portfolio? Set the stage Delphi on the move Customer Driven Engineering ADD... 10

11 Work Break Down Structure Market Spec TOP - DOWN customer requirements VERIFICATION systems & Sub Systems requirements Features VTS INTEGRATION INTEGRATION assembling BOTTOM - UP 11 lowest part level

12 Systems & Components Values OEM Vehicle integration + Attributes / Services Attributes / Services Attributes / Services Architecture System value Features Sub-Systems Functional Spec technical spec Architecture Features E N G I N E. Sub-Systems Functional Spec technical spec Architecture Features Sub-Systems Functional Spec technical spec component spec Component Value 12 component spec Physical implementation component spec

13 Traditional OEM / Supplier s Realm Vehicle Attributes / Services OEM Realm Attributes / Services Development effort C I Architecture Architecture Systems Features Features OEM Sub-Systems Sub-Systems Parts Supplier A Functional Spec technical spec component spec Supplier B Functional Spec technical spec component spec Physical implementation Supplier C S O P Suppliers 13

14 Strategy? Vision Mission Objectives Strategies GLOBAL LOCAL 14

15 Bonsai model Products Development 15 Divisional Knowledge J.V Universities Acquisition Supplier Technologies Government TechnologiesSubcontractors Scientific community

16 Global vs International Do not confuse GLOBAL & INTERNATIONAL Think Global Act local! 16

17 International Bonsai US Asia Europe 17

18 The Global Technology Tree Customer Integration Center XXXX Customer Integration Center NAO Truck Customer Integration Center Fiat Customer Integration Center Toyota Integrated Modular Body Doors & Interior Commun. Cockpits & Entertainment Power & Propulsion Vehicle Ride Dynamic & Handling Control E/E/E int.veh. Architecture comm. 18ext. comm. Electromechanical actuation Sensing Sensors Modular integration & delivery Vehicle Body Architecture controls

19 Regional Advanced Technology Leadership Diamond OEM Market Drivers & Gov t Regulations Physical Driving Conditions Available Resources Infrastructure 19 Competition and Supporting Industries

20 What s in the Soil should be an important determinant of footprint decisions Strong Govt. Support Software in India GPS in Japan Multiple fuel algorithms in Brazil ECUs in Singapore Good Education Endless supply of Engineers Low Capital Investment Flat panel displays Crazy network of Roads Strong consumer Electronics High gas prices Renewable fuel source like alcohol CNG Embedded Electronics Capability 20

21 Examples of Assessment of Product & Integration Complexity High Product Complexity Backup Aid Pressure Sensor MANAGE PERFORMANCE / COST TRADE-OFF Aftertreatment DCS Seat Belt RSAV ESS Receiver Glass Antenna Advanced Receiver Immobilizer /RKE Brakes Dampers SDM "DESIGN-IN" INTO VEHICLE SYSTEM Telematics Adaptive Cruise -Forewarn PODS Diesel CR Airbag DMS Magneride BCM EEDS Gas ECU Steering Columns Diesel ECU Low 21 Low DEFINE THE INTERFACE MANAGE CHANGE AT CUSTOMER Integration Complexity High

22 Value Proposition of Product Line drives Optimum Footprint Cost Driven Design Cycle - Mature technology products requiring cost based solutions Performance Driven Design Cycle - High clock speed products - Performance changes driven by customer factors, regulatory factors - Locate in low cost areas that also optimize total Engineering value stream. - Locate in areas of highest customer sophistication & availability of highest intrinsic skills regardless of cost. 22

23 Product Architecture Line drives Optimum Footprint Modular - Partition work to optimize cost and capacity utilization Integral Design - Maintain complete design value stream at one location to minimize Cost of Coordination & to grow Super-Engineers 23

24 Guiding Principles Major Guiding principles: CSC (Customer Support Centers) Very near customer locations SEC (System Engineering Centers) Near customer design location Manufacturing/Phase 2/3 Engineering At or near our manufacturing locations CEC (Component Engineering Centers) Generally in the customer region, low cost if possible as long as Engineering effectiveness is not sacrificed Utilize mature centers in sophisticated markets for TDP/ADP work. Use One Delphi approach whenever possible 24

25 Footprint PDCA Cycle Define Strategic Intent Customers / Products / Regions/ Revenues Execute Footprint Projects to achieve Plan Assess Total Engineering Workload Develop plan for distributing Headcount Partition Workload using Guiding Principles 25

26 Delphi US R&D Saginaw: S Flint: E&C; E&S Troy: T&I; DPSS; Core R&D Brighton: E&C Rochester : E&C Malibu: E&S Kokomo: E&S Indianapolis: E&C Dayton: E&C Warren: P Lockport: T&I 26

27 Delphi South America R&D Juarez: All Divisions Queretaro: P Piracicaba: E&C Sao Paulo: E&S 27

28 Delphi EMEA Key Figures Facilities 61 Wholly Owned Manufacturing Plants 23 operations in low cost countries (Russia, Poland, Czech Republic, Slovakia, Hungary, Romania, Turkey, South Africa and Morocco) 4 Joint Ventures 10 Technical Centers in Western and Eastern Europe and 9 Engineering centers 19 Customer Service Centers and sales offices Operating in 19 Countries Revenue $7.2B* Sales in 2005 Employees Approximately 49,000 * Preliminary figures 28

29 Delphi Europe R&D Systems Engineering Center Paris Established: 1991, inauguration new site 2005 Employees: 765 Focus: Driveline, Steering, Brake & Suspension Systems Systems Engineering Center Blois Established: 1959, transferred to Delphi 1999 Employees: 450 Focus: Single Point Injectors, Common Rail Systems (Pump, Injector, Rails) Systems Engineering Center Luxembourg Established: 1983 Employees: 704 Focus: HVAC, Engine Cooling,Engine Management & Energy Systems, Related Subsystems and Components Systems Engineering Center Krakow Established: 2000 Employees: 500 Focus: Suspension, Electrical/Electronic Systems, Interior, Energy and engine Management, Software development 29 Systems Engineering Center Illkirch Established: 1994 Employees: 156 Focus: Steering column & Steering wheel switches, Window lift switches, Headlight switches, Door, Trunk, Roof switches, Brake light, brake pedal, Transmission switches, Dashboard and middle console switches Systems Engineering Centers Bad Salzdetfurth and Nürnberg Established: 1951 / 2000 Technical Employees: 333 / 270 Focus: Reception systems Audio, MMM, Infotainment, Antenna, Telematics Wiehl-Bomig Amal Berlin Langlonsheim Goteborg Arjeplog Marienhagen Park Royal Gillingham Leamington Liverpool Systems Engineering Centre Wuppertal Established: Early 1980 s, inauguration new site in 2003 Employees: 1200 Focus: Integrated Vehicle E/E Systems (IVEES), Advanced Safety / Restraint Systems, Safety Electronics / Collision Avoidance,Door modules, Cockpits

30 Delphi Asia Pacific $3.2B year in Sales in 2004 $1.6 Billion in Consolidated Sales $1.6 Billion in Non-Consolidated Sales 6 Technical Centers - Japan, Korea, Singapore, India and China China Tech Center Opening in Wholly Owned Manufacturing Plants 16 Joint Ventures 14 Customer Service Centers Operating in 9 Countries Employing over 10,000 Employees in Consolidated Operations And more than 18,000 with joint ventures included Over 20 Customer Awards Earned in

31 Delphi Asia Pacific R&D JAPAN Technical Center Tokyo Established: 1992 Engineers: 98 Focus: Powertrain, Chassis, EEDS and Wireless Systems Expanding engineering capabilities into advanced chassis and powertrain systems including a full range of Diesel EMS products, Quadrasteer, MagneRide and Dynamic Body Controls KOREA Delphi Korea Corp Korea Tech Center Engineers: 97 (excludes Delphi P Seoul office with 33 engineers) Focus: Engine Management, Chassis and Thermal Systems Delphi Korea Corporation Munmak Plant Established: 1989 Engineers: 108 Focus: Advanced Safety Systems Combining synergies with KDAC to enhance low cost, small car component design capability INDIA Technical Center India (Bangalore) Established: 2000 Engineers: 360 Focus: Software Systems Expanding into Mechanical and Electrical CAE Planned growth to 500 engineers by Dec ASEAN CHINA Delphi Tsinghua Institute in Beijing Established: 1995 Function: Training & research China Technical Center (2005) Focus: Full range of automotive technologies with emphasis on EMS, Chassis and Wireless Systems Over a 250,000 man hours of technical training completed Shanghai technical center to be launched in 2005 with 500 engineers Singapore Design Eng. Center Established: 1989 Engineers: 140 Focus: Electronics & Safety Technology, Wireless Products, Engine Controls Units and Hybrid Electronics including Crash Sensors AUSTRALIA Local Applications Engineering for EMS, Exhaust, Fuel Handling and Steering Systems Global Center of Expertise for mini-car engine controls and electronic crash sensing modules 31

32 32

33 Delphi in Europe, Middle-East and Africa (EMEA) February,

34 Delphi EMEA Footprint UNITED KINGDOM - Plants: 5 - Eng/Tech Centers: 4 - Customer Service Centers: 1 NETHERLANDS - Customer Service Center: 1 (PS&S) GERMANY -Plants: 9 - Eng/Tech Centers: 7 - Customer Service Centers: 7 SWEDEN - Eng/Tech Center: 3 - Customer Service Centers: 1 RUSSIA -Plants/JV: 2 - Customer Service Center: 1 42 Plants in Western Europe 23 Plants in Central & Eastern Europe POLAND - Plants/JV: 6 - Technical Center: 1 - Customer Service Center: 1 34 LUXEMBOURG - Technical Center: 1 - Plants: 5 FRANCE - Plants/JV: 10 - Eng/Tech Centers: 3 - Customer Service Centers: 3 (incl PS&S) PORTUGAL MOROCCO - Plant: 1 SPAIN - Plants: 9 - Customer Service Center: 1 (PS&S) ITALY - Plants: 2 - Customer Service Center: 1 CZECH REPUBLIC - Plants: 4 - Customer Service Center : 1 - Plant: 1 HUNGARY - Plants/JV: 2 SOUTH AFRICA - Plants: 2 - Plant: 1 AUSTRIA SLOVAKIA ROMANIA - Plants: 2 TURKEY - Plants: 4 - Customer Service Center: 1

35 Delphi in France - Locations Villeron Cergy Tremblay Guyancourt (antenna) Douai DHC/DCC Donchery Florange St Aubin du Cormier Blois La Rochelle Strasbourg Illkirch Etupes Plants : 10 Technical Centres : 3 Customer Service Centres : 2 35

36 Delphi EMEA Product portfolio - Manufacturing in Eastern Europe, Middle-East & Africa Czech Republic Wiring Harness Cockpit Modules Hungary Body and Security Electronic Systems Chassis/Warning Systems Crash Sensing Electronics Infotainment Systems Wiring Harness CVC Compressor HVAC Poland HVAC Modules CRFM Modules, Condenser Radiators Heater Cores, Pipes Mechatronics Wiring Harness Canister, EGR Valve Chassis Modules Controlled Suspension Dampers / Damper Modules IAFM, Manifold Assembly, MPFI Throttle Body EPS Gears Halfschafts Steering Columns EEDS MMM 36 Body & Security Romania Wiring Harness Russia Wiring Harness Slovakia Wiring Harness Turkey Fuel Pump Fuel Injectors Nozzle Wiring Harness Morocco Wiring Harness South Africa Catalyst

37 37 Delphi in Asia Pacific

38 Delphi Asia Pacific Manufacturing Footprint 38 ASIA PACIFIC 14 wholly owned 16 Joint Ventures China Beijing Delphi Wanyuan EMS Co., Ltd. (JV) Delphi Saginaw Lingyun Driveshaft Co., Ltd. (JV) Delphi Packard Electric Systems Co., Ltd. (JV) Shanghai Delco Electronics & Instrumentation Co., Ltd. (JV) Shanghai Delphi Automotive Air Conditioning System Co., Ltd. (JV) Shanghai Delphi Automotive Door System Co., Ltd. (JV) Shanghai Delphi Emission Control Systems Co., Ltd (JV) Delphi Daesung Wuxi Electronics Co., Ltd. (JV) Delphi Shanghai Dynamics and Propulsion Systems Co., Ltd. (WO) Delphi Delco Electronics Systems (Suzhou) Co., Ltd. (WO) Delphi Electronics Suzhou Co., Ltd. (WO) Japan Calsonic Harrison Co. Ltd (JV) India Delphi TVS Diesel Systems Ltd.(JV) Delphi Automotive Systems Ltd. - Packard (WO) Delphi Automotive Systems Ltd. - Chassis/Harrison (WO) Delphi Automotive Systems Ltd. - Saginaw(WO) Delphi Automotive Systems Ltd. - Energy (WO) Joint Venture Wholly Owned Korea Korea Delphi Automotive Systems Corp Ltd (JV) KDS Co. Ltd (JV) Packard Korea Inc. (JV) Delphi Daesung Electric Co. Ltd (JV) Delphi Diesel System Korea (JV) Delphi Korea Corporation Munmak Plant (WO) ASEAN Delphi Packard Electric Malaysia Sdn. Bhd. (JV) Delphi Automotive Systems Singapore Pte Ltd (WO) Delphi Connection Systems - Specialty Electronics (WO) PT Delphi Automotive Systems Indonesia (WO) Delphi Automotive Systems Thailand. (WO) Australia Delphi Automotive Systems (Somerton) Australia, Ltd (WO) Delphi Automotive Systems (Clayton) Australia, Ltd (WO)

39 Delphi Asia Pacific ASEAN Thailand Customer Service Center Rayong Delphi Automotive Systems Thailand Ltd. Products: Brake Calipers Fuel Sender Module Fuel Pump Malaysia Bangkok Kuala Lumpur Technical Center Singapore Singapore Singapore Customer Service Center ASEAN Regional Office Technical Center Singapore Delphi Automotive Systems Singapore Pte. Ltd. Products: Airbag Sensors Pressure Sensors ECM RKE Body Control Modules Delphi Connection Systems - Specialty Electronics Products: Connectors Customers Supported Customer Service Center Shah Alam Delphi Packard Electric Malaysia Sdn. Bhd. (JV) Products: E/EDS Jakarta Indonesia PT Delphi Automotive Systems Indonesia (WO) Products: E/EDS 39

40 Delphi Asia Pacific Australia Customers Supported Delphi Automotive Systems Aust. Ltd. Customer Service Center Location: Somerton, Melbourne Product : R & P Steering Gear Total Fuel System Plastic Fuel Tank Canister MRA Melbourne Delphi Automotive Systems Aust. Ltd. Customer Service Center Location: Clayton, Melbourne Product : Catalyst Catalytic Converter 40

41 Delphi Asia Pacific China: Footprints Changchun, Jilin Province Customer Service Center (Changchun) Delphi Packard Electric Systems Co., Ltd. (Baicheng) (JV) Delphi Packard Electric Systems Co., Ltd. (Changchun) (JV) Customers Supported Beijing, Central Area Customer Service Center (Beijing) Delphi - Tsinghua Institute Beijing Delphi Wanyuan EMS Co., Ltd. (JV) Delphi Saginaw Lingyun Driveshaft Co., Ltd. (JV) Technical Center Shanghai (CTC) Shanghai, Coastal Area Technical Center Shanghai Delphi Anting Customer Service Center Delphi China Holding Co., Ltd. Delphi Packard Electric Systems Co., Ltd. (Shanghai) (JV) Shanghai Delco Electronics & Instrumentation Co., Ltd. (JV) Shanghai Delphi Automotive AC Systems Co., Ltd. (JV) Shanghai Delphi Automotive Door Systems Co., Ltd. (JV) Delphi Shanghai Dynamics and Propulsion Systems Co., Ltd. (WO) Delphi Delco Electronics Systems (Suzhou) Co., Ltd. (WO) Shanghai Delphi Emission Control Systems Co., Ltd (JV) Delphi Electronics Suzhou Co., Ltd. (WO) Delphi Daesung Wuxi Electronics Co., Ltd. (JV) Delphi (China) Technical Center Co., Ltd. (WO) Guangzhou, Guangdong Province Delphi Packard Electric Systems Co. Ltd. (Guangzhou) (JV) 41

42 Delphi Asia Pacific India Delphi Automotive Systems Ltd. - Energy & Chassis (WO) Plant : Gurgaon Products : Catalytic Converter Evaporative Canister Customer Service Center Gurgaon New Delhi Noida Delphi Automotive Systems Ltd - Chassis & Harrison (WO) Plant : Noida Product : Dampers Corner Modules Mounts HVAC Radiator Condensers Customers Supported Delphi Automotive Systems Ltd. - Packard (WO) Plant : Gurgaon Product : E/EDS Delphi Automotive Systems Ltd. - Saginaw (WO) Plant : Bangalore Product : Half haft Column Gear Technical Center Bangalore Bombay Bangalore Chennai Delphi TVS Diesel Systems (JV) Plant : Chennai Product : Diesel Injection Equipment Fuel Pumps Diesel Injectors Diesel Filters 42

43 Delphi Asia Pacific Japan Customers Supported Calsonic Harrison Co Ltd (JV) Product : A/C Compressors Technical Center Tokyo Utsunomiya Customer Service Center Customer Service Center Tokyo Toyota City Yokohama Customer Service Center Customer Service Center Customer Service Center 43

44 Delphi Asia Pacific Korea Technical Center Korea (KTC) Customers Supported Delphi Daesung Electric Co., Ltd (JV) Plant : Ahnsan Product : Switch,Relay, BEC Packard Korea Inc (JV) Plant : Cheonan Product : Wiring Harness Seoul Munmak Technical Center Sungwoo Korea Delphi Automotive Systems Corp (JV) Plants : Daegu, Yoju, Jincheon, Kunsan Product : Alternator, Starters,Ignition Converters, Brake Systems, Drive Axle, Steering Column/Gear/Pump, Radiator, Air-conditioning, Compressor, Airbag Module, ECM, FATC Delphi Diesel Systems Korea (JV) Plant : Changwon Products : Fuel Injection Components (injector, Pump, Nozzle) Changwon Plant : Kyungsan Product : Door Latch System Daegu KDS (Korea Door System) Corp (JV) Delphi Korea Corp Munmak Plant (WO) Plant : Munmak Product : Air bag, Seat belt 44

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