Bosch Mahle Turbo Systems implements GUARDUS MES for Quality Management

Feb. 15, 2011 - PRLog -- 300,000 revolutions per minute and temperatures up to 1,050 degrees make the exhaust gas turbochargers of Bosch Mahle Turbo Systems (BMTS) glow red. In order to ensure that the maximum quality standards in these conditions are met, BMTS decided to implement the GUARDUS Manufacturing Execution System (MES) in quality management.  The purpose of the “zero ppm” strategy of BMTS is to be able to immediately identify and evaluate even the smallest quality deviations (in µ). Therefore, it is important to plan and track all quality processes. “This is a very complex task because a turbocharger is made of up to 50 individual components provided by a great number of suppliers who are all part of the value chain,” stated Dr. Andreas Prang, managing director of Bosch Mahle Turbo Systems GmbH & Co. KG. For this reason, the field of application of GUARDUS MES must also integrate smoothly into the supply chain. The process parameters, measured values and inspection results of the entire supply chain will be centrally available in GUARDUS MES in the future, from supplier data through internal logistics and production up to final inspections of finsihed products. The inspection results of various suppliers can be combined by means of intelligent analysis methods in order to exclude potential sources of error as well as unsuitable combinations of components. Another important element of the software is the complete traceability of all components within the company and throughout the supply chain.

After an intensive selection process, BMTS decided to implement the software of the Ulm Germany based GUARDUS Solutions AG . Speaking about the benefits of the new solution, Dr. Prang said: “GUARDUS MES convinced us that they were the solution best adapted to our needs, especially through its extraordinary functionalities in quality management such as the online access to stamped construction drawings as well as the autofocus and the zoom function for the corresponding inspection characteristics which offer support to the work of the quality inspector. In addition, the comfortable change management in the inspection planning, easy handling of the application and highly efficient possibilities of evaluation options were also important factors that influenced our decision.”

A special analysis highlight is the so-called “torture stake.” Approximately 5,000 product and process data of various suppliers of BMTS are compared here and the critical characteristic combinations are automatically checked. “The components manufactured by various suppliers will be assembled during our manufacturing process. Therefore, we must be able to compare characteristics and inspection results in order to ensure that these components match perfectly,” explains Dr. Prang. In case of quality deviations, the GUARDUS users will be able to immediately identify the responsible suppliers and initiate efficient corrective actions.

The ERP system SAP and the machine data acquisition are connected to GUARDUS MES, thus providing integrated communication flows. This structure is also valid for test benches, measuring machines and manual measuring devices.

More information can be found on the GUARDUS quality modules here: http://www.guardus-solutions.de/en/solutions/quality-mana...

About BMTS

Bosch Mahle Turbo Systems was founded in 2008 as a joint venture of Bosch and Mahle. The aim of this young company was to become the preferred supplier of innovative solutions in the exhaust gas turbocharger segment and to meet the customer demands for flexibility, quality and cost-effectiveness. The headquarters of the company is located in Stuttgart, Germany. Additional locations are in Blaichach/Immenstadt in Allgäu and St. Michael ob Bleiburg in Carinthia. In 2009 the company started to build a new production plant in Austria, with an area of 10,000 square meters for production and assembly and 3,000 square meters for offices. Up to 3 million turbochargers per year will be manufactured and assembled in the Austrian town of St. Michael ob Bleiburg. After 18 months, BMTS can already see initial results: two high volume production orders from a major European automotive manufacturer. The turbocharging technology will be implemented in a gasoline engine for downsizing concepts and in a common rail diesel engine. Production will start at the end of 2011.

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About GUARDUS SOLUTIONS AG, with its offices in Germany, Canada, and Romania, is an internationally renowned software developer specialized in software simplifying manufacturing execution and quality management. With more than 25 years of experience servicing over 150 high quality and high responsibility discrete manufacturers in verticals including electronics, aeronautics, medical devices, plastics and automotive, GUARDUS has the expertise required to accelerate processes in forward looking enterprises.
More information at: http://www.guardus-solutions.de/en/guardus-solutions-ag.html