quality report

Sept/2013

Quality Report

2

Curitiba COPQ _ 2013

2,80%

4,79% 3,66%

3,10%

2,26% 2,52%

1,91% 2,19% 1,93%

3,19%

0%

1%

2%

3%

4%

5%

6%

-50.000

0

50.000

100.000

150.000

200.000

250.000

2012

jan/1

3

fev/1

3

mar/

13

abr/

13

mai/13

jun/1

3

jul/13

ago/1

3

set/13

out/13

nov/1

3

dez/1

3

COPQ - Curitiba - 2013 % of revenue

Warranty Claims Amount Concession Claims Amount Rework Amount

Scrap Amount Vendor Recovery Amount

target 2,24%

1,77%

1,57%

0,93%

1,85%

0,73%

1,30%

0,51%

1,60%

1,90%

1,29%

0,0%

0,2%

0,4%

0,6%

0,8%

1,0%

1,2%

1,4%

1,6%

1,8%

2,0%

-20.000

0

20.000

40.000

60.000

80.000

100.000

2012

jan/1

3

fev/1

3

mar/

13

abr/

13

mai/13

jun/1

3

jul/13

ago/1

3

set/13

out/13

nov/1

3

dez/1

3

COPQ - Trane Curitiba - 2013 % of revenue



target 1,24%

4,59%

13,3%

9,9%

4,7% 6,9%

4,4%

7,1%

4,4%

3,2%

11,6%

0%

2%

4%

6%

8%

10%

12%

14%

-50.000

0

50.000

100.000

150.000

200.000

250.000

2012

jan/1

3

fev/1

3

mar/

13

abr/

13

mai/13

jun/1

3

jul/13

ago/1

3

set/13

out/13

nov/1

3

dez/1

3

COPQ - TK Curitiba - 2013 % of revenue



target 3,89%

0,36%

1,81%

4,40%

1,90% 2,20%

3,90%

-3,30%

1,00% 1,26%

-4,00%

-3,00%

-2,00%

-1,00%

0,00%

1,00%

2,00%

3,00%

4,00%

5,00%

CO

PQ

Curitiba Quality Trends - ITS COPQ - % of revenue

COPQ COPQ target

3

Curitiba COPQ _ 2013

-

50.000

100.000

150.000

200.000

250.000

jan/1

3

fev/1

3

mar/

13

abr/

13

mai/13

jun/1

3

jul/13

ago/1

3

set/13

Warranty Claims Amount

Trane TK

Main issues September /2013

Thermoking - BRL90.000 on repairs of coils damged by bus chassi bracket

breakage to be recovered from Dealer not Thermoking responsibility

Trane Increase on warranty costs due to field service orders used to contain issues

in the field and improve problem solving

activities (finding root-cause on gemba)

Thermoking Leaking on compressor X-430 still impacting severelly the overall

costs

4

Curitiba ICQ DPPM - Top Ten Components _ 2013

$0

$10.000

$20.000

$30.000

$40.000

$50.000

$60.000

Cla

im D

oll

ars

Curitiba _ Trane _ Total Claim Dollars Top Ten Components Trailing Twelve Months Showing Reduction Project Impact

Total Claim Dollars

Estimated Dollars after Project Impact

Top Ten Components with Associated Projects Top Ten Components without Associated Projects

$0

$1.000

$2.000

$3.000

$4.000

$5.000

$6.000

$7.000

$8.000

$9.000

$10.000

Cla

im D

oll

ars

Curitiba _ ITS _ Total Claim Dollars Top Ten Components Trailing Twelve Months Showing Reduction Project Impact

Total Claim Dollars

Estimated Dollars after Project Impact


$0

$50.000

$100.000

$150.000

$200.000

$250.000

$300.000

$350.000

$400.000

Cla

im D

oll

ars

Curitiba Total _ Claim Dollars Top Ten Components Trailing Twelve Months Showing Reduction Project Impact

Current Total $s

Total $s After Project Impact


$0

$50.000

$100.000

$150.000

$200.000

$250.000

$300.000

$350.000

$400.000

Cla

im D

oll

ars

Curitiba _ TK_ Total Claim Dollars Top Ten Components Trailing Twelve Months Showing Reduction Project Impact

Current Total $s

Total $s After Project Impact


5

TK Shaft Seal Leaking - Compressor X430

6

Curitiba Quality Trends _ 2013

7

Trane ICQ DPPM - Top Ten Components _ 2013

0

200000

400000

600000

800000

1000000

1200000

DP

PM

Rat

e

Chiller _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate

DPPM After Project Impact

Top Ten DPU Items with Associated Projects Top Ten DPU Items without Associated Projects 0

500

1000

1500

2000

2500

3000

3500

4000

4500

DP

PM

Rat

e

Curitiba _ Wave _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate


Top Ten DPU Items with Associated Projects Top Ten DPU Items without Associated Projects

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

DP

PM

Rat

e

Self _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



0

10000

20000

30000

40000

50000

60000

DP

PM

Rat

e

Condensador _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



8

Curitiba Main projects_ 2013

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

DP

PM

Rat

e

Roof Top _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



Main actions

Thermoking A3_ WR 01/13_Shaft Seal Leak - Compressor X430

Thermoking 8D_62/13 Leaking through vibrasobers

Thermoking Repair on coils to be refunded by Dealer (not Thermoking responsibility)

Thermoking Change of pulley from supplier General Machine to Linnig

Trane 8D - 0335/13_ Condensing unities Compressors failure analysis

Trane 8D - 0319/13_Improvement of design of Fans, Resourcing of supplier and improvement on belt tension and pulley alignement process

Trane Improvement on Brazing Quality implementation of Brazing Excellence Program

9

Brazing Quality _ Internal DPMO

-

500

1.000

1.500

2.000

2.500

Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec

Chiller _ Internal DPMO

-

500

1.000

1.500

2.000

2.500

3.000


'AIR HANDLERS_ Internal DPMO

-

100

200

300

400

500

600

700


Self _ Internal DPMO

-

200

400

600

800

1.000

1.200

1.400

1.600

1.800


Roof Top _ Internal DPMO

10

-

500

1.000

1.500

2.000

2.500


'CONDENSING UNIT _ Internal DPMO

-

5.000

10.000

15.000

20.000

25.000

30.000


Trane _ Internal DPMO

Brazing _ Internal DPMO

11

Thermoking _ DPPM

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

4000000

DP

PM

Rat

e

LRT _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate


Top Ten DPU Items with Associated Projects Top Ten DPU Items without Associated Projects0

200000

400000

600000

800000

1000000

1200000

1400000

DP

PM

Rat

e

V100 _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



0

500000

1000000

1500000

2000000

2500000

3000000

3500000

4000000

DP

PM

Rat

e

SR50 _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

9000000

10000000

DP

PM

Rat

e

DP _ ICQ DPPM - Top Ten ComponentsTrailing Twelve Months Showing Reduction Project Impact

DPPM Current Rate



12

Plant FPY

85%

73%

85%

92% 93% 93% 97% 96% 95%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

FP

Y

FPY - Plant Curitiba

Target - 95%

84%

68%

83%

91% 94% 93% 98% 97% 96%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%


FP

Y

FPY Trane Curitiba

89% 94% 94%

96%

87% 92%

86% 87%

77%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%


FP

Y

FPY - Thermoking Curitiba - 2013

Target -

95% 67%

78%

50% 48%

79% 73%

47%

55%

39%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%


FP

Y

FPY ITS Curitiba

Target - 95%

13

Customer Claims

40

35 34 33

20 19 17

14

27

23

0

5

10

15

20

25

30

35

40

45

2012 jan/13 fev/13 mar/13 abr/13 mai/13 jun/13 jul/13 ago/13 set/13

Customer Claims TK - 0 km

6

12

15 14

7

5

2

22

20

0

5

10

15

20

25

jan/13 fev/13 mar/13 abr/13 mai/13 jun/13 jul/13 ago/13 set/13

Customer Claims Trane - 0 km

1

0

1

7

6

4

0

4

5

0

1

2

3

4

5

6

7

8

jan/13 fev/13 mar/13 abr/13 mai/13 jun/13 jul/13 ago/13 set/13

Customer Claims ITS - 0 km

49

315

Curitiba _ Reclamaes de cliente _ SET 2013

Fechadas

Abertas

quality report

Documents

claim dollarscuritiba

s total

curitiba copq

revenue copq copq target

associated projects

revenue warranty claims

concession claims

warranty costs