Delphi Diesel Systems Romania

People considerations

in developing a new high technology

production site

1. Introduction

2. Selection of location

3. Mother Site

4. Functional Mentors

5. Site Culture Development

6. Competency Development

7. Progressive technical evolution

8. University and Government considerations

Content

Delphi in Romania

4 manufacturing plants

+ 9 000

employees

3 Electrical/Electronic

1 Powertrain

18

years of

expertise

1997 Sânnicolau Mare

2004 Ineu

2011 Moldova Nouă

2012 Arad Engineering Office

2007 Iaşi

Background of Iasi Facility

1 plant (sqm 35k)

Employees: over 2,000

Annual no. of injectors: 4,759,883

Annual no. of pumps: 1,468,061

Customers:

Daedong, Doosan, Tata, GM, Great Wall,

Hyundai, JCB, KIA, LS Mtron, PSA,

SsangYong , VW

Pumps

Injectors

Geography History

Plant’s facts

2007 Iasi plant announcement

First Employee Hired

Moved into Brownfield

2008 Training – Pump & Injector

First Customer Visits

Broke ground for Greenfield

2009 Brownfield to Greenfield Transfer

24

1012

1416

22 22

02

7

1214

16

19

23

0

5

10

15

20

25

2008 2009 2010 2011 2012 2013 2014 2015

Pump A&T Inj A&T

Growth of Pump & Injector references

First Engineering School “G. Asachi”

Oldest Romanian University “Al. I. Cuza”

over 60,000Studentseach year

321 606 city population

Over 500.000 Inhabitants peri-urban area

2nd largest city in Romania

Selecting the location: Iasi, Romania

Iasi

10 Technical high-schools

and

5 Technical Colleges

7 technical faculties offering

over 1000 young talents

to select and hire each year

Unemployment rate >6%

for the region

Delphi Confidential6

Open to teach and train

Stable business processes

Technology lead

Similar products

Similar processes

Linked to R&D Center

Assigning a “Mother Site”

Delphi Confidential

Mentors for Plant Staff 2008 to 20152008

Plant Manager,

Delphi Diesel Systems Romania

Operations

Manager

Plant ME

Manager

Plant Facility & IT

Manager

Production Control & Logistics

Manager

Product Engineering

Manager

HR - EH&S

Manager

Finance & TCM

Manager

Plant Quality

Manager

Purchasing Manager

Plant LEAN/IE Manager

Local with mentor

Expat assignment

Independent Local

Plant ME Manager

Plant Facility & IT

Manager

Production Control &

Logistics Manager

Product Engineering

Manager

HR - EH&S

Manager

Finance & TCM

Manager

Plant Quality

Manager

Purchasing Manager

Plant LEAN/IE Manager

2015

Plant Manager,

DDS Romania

Recruit Plant Staff

Train, coach, support

Global org. connection

Help resolve issues

Operations

Manager

Lead Administrative AssistantLead Administrative

Assistant

Delphi Confidential

Respect – Integrity - Responsibility – Accountability – Proactivity - Teamwork

Lean

Collective Focus – Business Priorities

Customer /

Partner

Feedback

Structured

Problem

Solving

React to

Abnormal

From

Normal

Technical

Competence

Growth

Delphi Vision & Mission

Iasi Vision & Mission

Developing a Site Culture at Delphi Iasi

Delphi Confidential

Culture Deployment

Build a TEAM!

Vision and

Mission

bottom up input

Plant Staff trains salaried

employees

Plant Manager trains Plant

Staff

Plant Staff & Key leaders train

Production Supv.

Operators trained in special

sessions

Employee’s feed-back nurtures Culture

Delphi Confidential

Competency: Partnerships with Education

Technical University Partnership Gh. Asachi

The partnership includes: consultancy and educational

support on providing feed-back and input related to

curricula per business requirements;

Over 100 students annually actively involved in the

summer practice programs.

11

Machine donations (turning, milling & measurement)

Scrap parts & protective equipment to be used

during student laboratories sessions and protective

equipment

Technical University’’Ghe.Asachi’’– professors visits

Delphi Confidential

Delphi Workshops organized in the University

Machine Construction and

Industrial Management Faculty

Electrical Engineering Faculty

Electronic Faculty and IT

Mechanical Engineering Faculty

Delphi Confidential

Regular interaction with Students

13

Technical Univeristy ’’Gheorghe Asachi’’

students visits

Technical high-school

students and professors visits

Practice Programs for Students

Technical and Career Growth Process

Junior Engineers

Fresh Graduates

Technical Students

Mfg. Engineers

Production Eng.s

Tech.

Leaders

Management

Mentors develop staff

Skills matrix

Training Pyramids

Technical and Career Growth Process

Technical Students & Fresh Graduates Training Programs

Evaluation after 6+6 months

Evaluation after 6 months

470Fresh & Technical Students validated

2008 - 2015

Assessment center

Initial recruiting and

screening

Training Center

Year Pump A&T Drive Shaft HousingHydraulic

Head

Injector

A&TValve Nozzle

2008 2 0 0 0 0 0 0

2009 4 1 1 2 2 0 0

2010 10 5 4 2 7 0 0

2011 12 8 6 3 12 1 5

2012 14 9 7 3 14 10 11

2013 16 10 9 3 16 11 12

2014 22 11 10 4 19 12 15

2015 22 13 11 4 23 17 19

Technical evolution enabled by competency

No. of References

0

500

1000

1500

2000

2500

Q1-

08

Q2-

08

Q3-

08

Q4-

08

Q1-

09

Q2-

09

Q3-

09

Q4-

09

Q1-

10

Q2-

10

Q3-

10

Q4-

10

Q1-

11

Q2-

11

Q3-

11

Q4-

11

Q1-

12

Q2-

12

Q3-

12

Q4-

12

Q1-

13

Q2-

13

Q3-

13

Q4-

13

Q1-

14

Q2-

14

Q3-

14

Q4-

14

Q1-

15

Q2-

15

Q3-

15

2008 2009 2010 2011 20132012 2014 2015

First ME

leaders

Al housing

pump

launched

Pump Pilot

line

PE started

Product

Validation

Lab

Product

Design

Center

Competency enables Increased Responsibility

Nozzle &

Valve

Launch

Number of employees

Industry Attractions - Education

Technical High

Schools

Flexible

schedulesStudent

programsAutomotive

curriculums

Industry Attractions – HCC transition

Embrace Globalization

Organizational Change: High volume producer to Technology Lead Sites

Automation, Manufacturing and

Industrial Engineering

Global multi-site change management

Technical language translation

Soft skills training in working with foreign cultures

Re-educate employees to expanding

international service and support industries

Suppliers expanding globally

Foreign immigration and labor laws

International equipment certification

International finance

Customs laws

International tax laws

Global market work schedules

7 day work schedules

Flexible vacation schedules

Foreign culture training

Languages training

Industry Attractions – BCC transition Primary government contacts to aid in following local processes and procedures

Airport connections for HCC(high cost country) support personnel and BCC(best

cost country) trainee frequent travel

International Schools for mentors and people on assignments

In summary, the people behind the technology

make a new production site effective.

Mating experienced mentors with available talent

to nurture site culture and competency growth

are fundamental considerations for success.

Thank you!