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WABCO Confidential and ProprietaryWABCO Confidential and Proprietary
Remanufactured Goods in the Commercial Vehicle Industry
How operations drive customer satisfaction
Dr. Salvador Munoz – REMAN Product Line Leader
ReMaTec Circular Economy Seminar
June 15, 2015
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Listed on NYSE with the stock symbol WBC
GLOBAL TECHNOLOGY LEADER
$2.8 Billion
11 000 Employees (1,650 Engineers)
21 Manufacturing Locations
Commercial Vehicle Industry
Sales in 2014
In 34 Countries
On 4 Continents
The leading global supplier of commercial vehicle technologies
About WABCO
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Market Focus
• ASHOK LEYLAND• CNHTC• DAEWOO• DAIMLER• FAW• FIAT• HINO MOTORS• HYUNDAI• KAMAZ• KINGLONG• MAN• PACCAR• SCANIA• TATA MOTORS• VOLVO• YUTONG BUS
• AUDI• BMW• DAIMLER• FORD CAR
• GENERAL MOTORS
• MANDO• MOBIS• PSA• SANGYONG• CHRYSLER
• SUPPORTING FLEETS AND TRUCK OWNERS OVER VEHICLE LIFETIME
• DISTRIBUTORS• WORKSHOPS• FLEETS
• AGCO• BEML• CATERPILLAR• CLAAS• CNH CASE NEW
HOLLAND• JOHN DEERE• LIEBHERR• SANY• TANDANO FAUN• ZOOMLION
• CIMC• FACCINI• GUERRA• GREAT DANE
TONAR• KÖGEL• KRONE
• SCHMITZ CARGOBULLTIRSAN
• WABASH
TRUCK & BUS OFF-HIGHWAY AFTERMARKETCARTRAILER
Products, systems, services and support for vehicle manufacturers and aftermarket customers
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The Technology & Innovation Leader
2009
2000
2004 2007 2008
2001• Anti-Lock Braking System
(ABS)
• Pneumatic TransmissionAutomation System
• Trailer EBS
• Electronic Braking System (EBS)
• ECAS for automotive
• Electronic Stability Control (ESC)
• Hydraulic Transmission Automation System
• OnGuard™ Collision Mitigation System
• OnGuardMAX™ Autonomous Emergency Braking System
• OptiDriveTM Transmission Automation System
• Trailer Telematics
• ESCsmart™ Simulation System
• OnGuardPLUS™ Advanced Emergency Braking System
• New Generation Automated Manual Transmission
• Modular EBS
• OnLane™ Lane Departure Warning System
• EBS for Hybrid Drivelines
• Hydraulic ABS
2010 2012/20132011
Pioneering technologies has defined WABCO for the last several decades
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• Award ‘Heavy Duty Remanufacturer of the Year’ by APRA*
• Award ‘Most popular Remanufacturerin China’ by DUXES
• Certification ISO/TS 16949:2009 acquired Rochester Hills & Stanowice
• Start of production in Jinan, China, JV in Mexico
• Establishment of WABCO Reman Solutions
• Westinghouse Air Brake Company (WABCO) founded in USA by George Westinghouse
1869
• Start of production in Rochester Hills, USA & Stanowice, Poland
2011
2013
2010
2012 2014
WABCO REMAN SOLUTIONS
Fast global expansion
Milestones
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BRAKING SYSTEM MODULATORS
ELECTRONIC UNITS
HYDRAULIC MOTORS
BRAKING SYSTEMS
ACCOMPRESSORS
AIRCOMPRESSORS
Reman ProductsMECHANICS HYDRAULICS ELECTRONICS /
MECHATRONICS
TURBO CHARGERS
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LandfillUser(Re)ManufacturerFoundryExtraction
RemanRecycle
Reman Benefits
Material (kg) CO2 (kg) Energy (MJ) Logistics (tkm)
New
Reman0,43
3,49 17,01
8,03
281
122
45,2 44,1
-88%
-53% -56%
-2%
Source: APRA EuropeExample for a starter
REMAN: The ecological solution of the future
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A REMANUFACTURED PART FULFILLS:• a function which is at least equivalent
compared to the original part. • It is restored from an existing part
(core), using standardized industrial processes in line with specific technical specification remanufactured part is given the same warranty as a new part and it clearly identifies the part as a remanufactured part and the remanufacturer.
What is remanufacturing?
COMMON DEFINITION OF APRA, ACEA, CLEPA, FIRM and VDAA remanufactured part is different from a reused, repaired, refurbished, reworked or reconditioned part
A CORE is a used part which is intendedto become a REMANUFACTURED PART.During reverse logistics it is properlyprotected, handled and identified for remanufacturing to avoid damage and preserve its value.A CORE is not a waste or scrap and willnot be reused before remanufacturing.
A CORE:
As good as new
WABCO Confidential and Proprietary
Who is my customer ?
Translating the Voice of the Customer9
OES WORKSHOPSDISTRIBUTORS FLEETS
Premium Quality at Affordable Price
Operational efficiency
Parts Replacement
Maintenance solutions
Warranty – same as newPerformance – same as new
30% - 40% lower price vs newDeliver worldwide Low effort core return
Speed of implementation
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Rigorous Remanufacturing Process
DISTRIBUTIONCLEANING
DISASSEMBLY
REASSEMBLY
RESTORING TESTING
CORE MANAGEMENT & SORTING
SIX SIGMA LEAN processes with the added certified security of ISO TS 16949:2009
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DISTRIBUTOR
COLLECTION
POINT
SCRAP
3-6 months
CORE
Core Return – The Concept
WABCO product with surcharge
Container with all kind of cores
Information flow
Goods flow
Legend:
Validation:‐ Quality‐ Part number‐ Quantity
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5
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Low effort core return
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Core Return in EU
Distributors
Selected cores transport to WRS
Collecting and sorting points
Full coverage in Europe
Low effort core return
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• Fast and easy core management process (cores pick-up within 48 hours)• Two weeks maximum credit time • Full cover collection points across Europe• Reverse logistic process & packaging guidelines in 21 languages
Core management & sorting
WRS takes responsibility for the entire lifecycle of the products.
Low effort core return
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Technical excellence
Our producing process is performed by highly advanced machines
CLEANINGSpecialized cleaning:• blasting, • ultrasonic washing,• high pressure • paint stripping• chemical washing
DISASSEMBLYall parts are completely disassembled with great care to protect and prepare key components for processing.
REASSEMBLYstate of art technicsare used to achieve consistent quality in reassembly. Wearparts are replacedwith qualified new components.
RESTORINGthe wear surface to original specifications even to the micron level:• CNC machining• lapping • re-honing• chromating• electronic -
components replacement
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2
3 4 5
3 4 5
1 6 7
30% ‐ 40% lower price vs new
Salvageability > 75%
30% ‐ 40% lower price vs new
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Testing
• 100% of ECU on board (ICT) and functionally tested
• End of Line (EOL) test same as new
State-of-the-art processes such as ‘on board’ testing.
TEBS-D TESTING AIR COMPRESSOR TESTING
Warranty – same as newPerformance – same as new
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UNITES STATES OF AMERICA
Product availability is key to customer satisfaction.
GERMANY
CHINA
Pluakdang
HannoverNeunkirchenHannoverMannheim
CharlestonRochester Hills
BRAZILCampinasCampinas
FRANCEClaye
JinanQingdaoJinanTaishanQingadao
THAILAND
Higashimatsuyama
JAPAN
WrocławStanowice
POLAND
DubaiUAE
RussiaRUSSIA
MadridSPAIN
HOLLANDMeppel
SWITZERLANDBern
Distribution
Deliver worldwide
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Global
WABCO Reman Solutions is the first and only company licensed to remanufacture air compressors in China; part of our commitment to serve our customers globally.
WABCO Reman Solutions operates through WABCO's globally connected network
Global Headquarters
Joint Ventures
Wabco Reman Solutions
INDIAChennaiMahindra World CityJamshedpurLucknowPantnagar
THAILANDRayong
SOUTH KOREAPyungtaek
CHINAJinan (2plants)QingdaoTaishanShanghai
NETHERLANDSMeppel
GERMANYGronauHanoverManheim
JAPANTokyo
RUSSIAMiass
POLANDWroclawStanowice
FRANCEClaye Souilly
BELGIUMBrussels
UNITED STATES OF AMERICARochester HillsCharlestonTroyHebron
MEXICOSan Luis Potosi
BRAZILCampinas S.P.
Deliver worldwide
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Locations
Strong global footprint
STANOWICE, POLANDSize: 5.000 m2
Quality Certification: TS16949 and ISO14001
ROCHESTER HILLS, USASize: 5.865 m2
Quality Certification:TS16949 and ISO14001
SAN LUIS POTOSI –JV MEXICOSize: 1200 m2
Quality Certification: TS16949 and ISO14001
JINAN, SHANDONG, CHINASize: 5040 m2,Reman 293 m2Quality Certification: TS16949 and SH
Deliver worldwide
WABCO Confidential and Proprietary
Who is my customer ?
Translating the Voice of the Customer20
OES WORKSHOPSDISTRIBUTORS FLEETS
Premium Quality at Affordable Price
Operational efficiency
Parts Replacement
Maintenance solutions
Warranty – same as newPerformance – same as new
30% - 40% lower price vs newDeliver worldwide Low effort core return
Speed of implementation
WABCO Confidential and Proprietary
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