Sales in China grow a nominal 27 percent to 6.4 billion euros
Bosch still sees good growth opportunities in China
Some 930 million euros invested in local expansion in the past three years
Auto Shanghai 2015: Bosch presents integrated mobility solutions for the Chinese market
Shanghai / Stuttgart – Bosch, a leading global supplier of technology and services, registered consolidated sales of 6.4 billion euros in China in 2014, growing year on year by 27 percent. Speaking at the annual press conference of Bosch in China, Peter Tyroller, the member of the board of management of Robert Bosch GmbH responsible for Asia Pacific, said: “This significant growth in China is a major factor in our good business development in Asia Pacific. The entire region remains an important growth driver for the Bosch Group.” Bosch is confident that it will continue to register healthy growth in the years to come: “We want to actively shape the development of the Chinese market, and take advantage of the wealth of opportunities arising above all from connectivity, automation, and electrification, as well as energy efficiency”, Tyroller added.
Further localization as success factor To further expand local manufacturing operations and build up research and development in China, the Bosch Group has invested a total of close to 920 million euros in China over the past three years. In 2014 alone, the investment amounted to almost 330 million euros. “Our localization strategy in China is paying off, as our business success in the country shows,” Tyroller said. For instance, the Bosch Mahle Turbo Systems joint venture opened its first plant in Shanghai in 2014, where it will be manufacturing turbochargers. In this way, the company is responding to the country’s steadily growing demand for energy-saving and emissions-reducing automotive technology. The second Bosch diesel technology plant is to be opened in Qingdao, eastern China, this year. Bosch’s Thermotechnology division plans to set up a joint venture with the Chinese manufacturer Midea to manufacture variable refrigerant flow (VRF) heating and air-conditioning systems for commercial buildings.
Auto Shanghai 2015: Bosch presents integrated mobility solutions At this year’s Auto Shanghai (April 22-29), Bosch will be presenting integrated mobility technologies and solutions focusing on connectivity, automation, and electrification. China is the world’s largest automobile market. Bosch can help meet some of that market’s demand for products that enhance road safety, reduce emissions, and save energy. The Bosch booth at Auto Shanghai will be in exhibition hall 4.1, 4A05.
Bosch in China Bosch has been present in China since 1909. Following Germany and the U.S., China is the third largest market in the world for Bosch, generating sales of 6.4 billion euros in 2014. Following integration of the former joint ventures BSH Bosch und Siemens Hausgeräte GmbH and ZF Lenksysteme GmbH, Bosch employs 53,000 associates in China – the largest Bosch workforce outside Germany.
“Make in India” initiative offers opportunities for connected industry
Software solutions for connected manufacturing in India
Bosch focuses on technologies that are “Invented for life” and tailored to local market
The Bosch Group is forecasting strong growth over the next few years for India, this year’s partner country of Hannover Messe 2015. The company expects to see positive development in the country over the medium and long term. As early as this year, India’s economy is expected to grow by six percent. “The new Indian government is systematically addressing key issues such as infrastructure, education, and reducing bureaucracy. We are confident that this will positively impact the country’s development,” said Dr. Steffen Berns, president of the Bosch Group in India. Bosch has been active in India since 1922 and continues to see a healthy business climate on the subcontinent. “Especially in the areas of mobility, infrastructure, industry, energy, security, packaging, and healthcare, there are many opportunities for our products and solutions. The field of connected production also opens up possibilities for Bosch in India,” Berns said.
Bosch uses connected production in India The new “Make in India” business initiative, for example, aims to advance industrialization in the country and modernize production. “We believe that the use of intelligent and connected solutions in manufacturing will play an increasing role in India. Bosch is very well positioned for this,” Berns said. With regard to connected industry, Bosch is a leading global provider and exponent. The supplier of technologies and services offers a broad range of solutions such as drives, automation solutions, sensors, software, and predictive maintenance. In order to meet the standards required for connected production, Bosch is also cooperating closely with partners in Germany and abroad. One example is the company’s partnership with IT companies Tech Mahindra in India and Cisco in the United States. In conjunction with these two partners, Bosch is driving forward connectivity in industrial tools as part of the Industrial Internet Consortium.
Industry 4.0: examples from India Bosch’s largest development center outside Germany is located in Bangalore and Coimbatore in southern India, and employs some 12,000 associates. One of the center’s areas of focus is on developing solutions for connected industry. For instance, its engineers have developed software which links all the machinery in a manufacturing facility and enables the collection and analysis of data in real time. This enables production status to be monitored and material shortages as well as machine failures to be resolved quickly.
Since 2014, the development center in Bangalore has also been focusing on big data analytics. A software model for analyzing big data collected in manufacturing was also developed there. The model performs statistical analysis on the basis of algorithms, thus enabling specific predictions to be made and changes to be detected. It can be employed in factories, for instance, to reduce throughput times, enable predictive maintenance, and optimize resource use, as well as to improve the management of capacity, inventory, and logistics. Bosch uses manufacturing data at its plants in Bangalore and Jaipur, for example, to shorten throughput times in the testing and calibration of diesel injection pumps.
Worldwide, 20 of Bosch’s more than 250 plants are already equipped with RFID (radio frequency identification) logistics solutions. These are used in Bosch’s diesel plant in Nashik, for example, where RFID radio tags monitor the workpieces’ progress through the factory by identifying the position of transport crates. The tags enable precise details to be known about the process steps each piece undergoes and when the injectors will be ready. This information can then be used as the basis for drawing up a schedule for packing, shipping, and installation.
Technologies “Invented for life” and tailored to local requirements In emerging markets like India, Bosch focuses on locally developed solutions that are tailored to the requirements of the local market. For instance, Bosch in India has successfully developed an electronic hitch control for Indian tractor manufacturers as well as a common-rail system for small engines. One of the Bangalore development center’s recent innovations is a compact retinal camera with special software that can detect conditions such as cataracts at an early stage. Last year, Bosch also developed an affordable and robust engine management system that is specially designed for the booming Indian two-wheeler market.
A proven model for developing skills “The well-educated workforce and ease of communication in English increase India’s attractiveness,” Berns said. Bosch has operated a training center in India for more than 50 years using the proven Bosch model of dual education. Every year, around 60 young people start an apprenticeship at the Bosch Vocational Center in Bangalore. Bosch trains more people than it actually needs in India, and in this way fulfills its social responsibility to provide vocational training for young people.
Bosch in India Over the past ten years, Bosch has more than tripled its sales in India, generating 1.2 billion euros in 2013. The company currently employs more than 28,000 associates at eleven manufacturing and development sites. Since 2010, the Bosch Group has invested around 680 million euros in the expansion of manufacturing and research facilities in India, including some 160 million euros in the past year alone. In 2014, a new research and technology center opened in Bangalore which is focused on the development of connected technologies for the internet of things. (Remarks: 2014 Bosch India sales will be announced in May 2015)
Storage reduced by around a third using RFID transmission technology
Declining error rates thanks to sensors
Stuttgart – Bosch is boosting the competitiveness of its factories by applying its own Industry 4.0 solutions. At present, the Bosch Group has over 100 projects on this topic, with this number rising rapidly. A few reports from Bosch associates demonstrate what benefits these solutions offer:
Turning inventory into a walk in the park Zhao Chunya, product planner in Suzhou, China: “Before, we had to devote a lot of time and effort each year to doing inventory. Plant 1 alone has four manufacturing areas, each with up to 2,500 machines, test benches, and measuring equipment. The process sometimes took up to a month for ABS manufacturing alone, with some of the equipment standing idle during that time. We used to print out lists and head off in search of the equipment. Sometimes we had to crawl between the machines to find the stickers with the information. All that has changed completely. Now I’m able to do it alone in just four hours. We fitted all of the machines and equipment with RFID transponders. This allows objects to be identified without physical contact. We then built this RFID trolley with antennas on the side. I download an inventory list from the network to my laptop. Then I push the trolley through the aisles along a prescribed route. Little by little, the machines and devices are automatically identified thanks to the RFID technology. As they are, more and more lines on my spreadsheet turn green. It cuts the time needed for inventory by 97 percent, or 440 man-hours. In the future, we plan to replace the RFID transponders with connected sensors. That would mean we wouldn’t even need to do the walking part. And I could spend more time focusing on my real job. I am a product planner, after all!”
The warehouse talks to the supplier Attila Szabó, machine accessories and spare parts coordinator in Hatvan, Hungary: “We have about 5,000 machines for the various production and testing processes at our plant, which are very different from one another. Some of them are 15 years old, while others are much newer. That’s why we need lots of different spare parts. So far we’ve equipped the majority of them with RFID transponders. As a result, we need only twelve man-days for inventory – instead of 180. I can focus more on improvement processes now. What’s more, we’ve also partly automated the ordering process thanks to this technology. A part is automatically reordered from the supplier once its quantity dips below a certain level. We used to do that by sending an e-mail, but the process took more than two and a half days. We’ve already implemented this for 14,000 of the 25,000 part types. Soon it will be all of them.”
The right person to call in an emergency Krisztián Anda, service technician in Hatvan, Hungary: “I just got a text message asking me to come to this production line in circuit board assembly right away. The operator reported a fault using a small, portable computer right at the machine. Our new system automatically notified me immediately. In the past, the operator would have informed his or her supervisor of a problem first, then the supervisor would have called the service technician. That would sometimes take 15 minutes. And I used to get called a lot, even though I’m not an expert for this line. Thanks to the small computers and new software, we’ve cut the reaction time. Now, on average, it’s much less than five minutes – sometimes only about 30 seconds. I can submit the support ticket on site directly into the system. I don’t need paper anymore. Plus, all of us are only called out to look at machines that we’re familiar with, thus enabling fast and effective troubleshooting.”
Learning with sensors Patrick Arnold, skilled production worker in Reutlingen, Germany: “We manufacture the power electronics for electric and hybrid vehicles on this production line. At my station, I tighten a part onto radiators. We have now equipped the Bosch Rexroth nutrunner with a sensor that measures the speed at which I put the screw in and gives me feedback. The figures are entered directly into our computer system. It additionally stores the torque and rotation angle for each screw so that we can analyze it in greater depth later. It gives you a better feel for what you’re doing and improved quality assurance.”
Storage in production reduced by nearly one third Andreas Müller, logistics and RFID expert at Bosch: “At the Homburg plant, we produce injection nozzles for diesel engines. There, RFID radio tags monitor the workpieces’ progress through the factory by identifying the position of transport crates. This enables precise details to be known about the process steps each piece undergoes and when the injectors will be ready. That data, in turn, can be used to determine when the finished product will be packaged, shipped, and installed. Bosch has involved one of its suppliers (Variopack) and one of its customers (Opel) in this process, so that we can all jointly plan and produce better. Using this system, Bosch has been able to boost productivity by ten percent in logistics alone – and reduce storage in production by nearly one third. To ensure that the systems work to the advantage of all stakeholders, we established a common standard for exchanging data.”
Background: RFID technology The term RFID (radio frequency identification) refers to technology that can identify objects quickly and without physical contact. RFID tags containing a code can be mounted on transport crates, spare parts, or tools, for example. A scanner uses radio waves to read the code. Depending on the type of RFID technology used, this works over a distance of anywhere from a centimeter to a meter.
Stuttgart – At Hannover Messe 2015 (April 13-17), Bosch will show how it is driving connected industry forward as both a leading supplier and a leading user with its innovative, tried-and-tested solutions. The technology and services provider will demonstrate how to improve manufacturing flexibility by interlinking the virtual and real worlds. Here are a few selected examples:
Connected hydraulic power units By setting up a wireless connection to its existing IT systems, a company can use that link to quickly and flexibly incorporate the energy-efficient hydraulic power units in Bosch Rexroth's ABPAC series into its production environment (“plug and play”). The units also forward the data collected by the sensors to the higher-level control system. This means the overall status of the system can be displayed there, as well as on authorized smartphones and tablets. Users see the unit's current operating status and can respond to anomalies in good time.
Process Quality Manager The Process Quality Manager software solution by Bosch Software Innovations monitors and documents production processes in real time. Thanks to its analysis function, the Manager can help identify errors and contain causes before faults even occur. Reporting functions allow constant monitoring of the success of the measures taken. Details: http://bit.ly/1y4FceP
Mobile production assistants: APAS family The mobile production assistants of the APAS family – the APAS assistant, the APAS inspector, and the APAS flexpress – work hand in hand with their human “colleagues.” Usable in a variety of situations and fully connected, the assistants support the trend toward adaptable production, with fast manufacturing facilities that can be retooled semiautomatically. Flexible assistants such as these play a major role in production. The APAS assistant is the first system to be certified for direct human-machine collaboration by the German Social Accident Insurance (DGUV) association. Details on the APAS family: http://bit.ly/1FSTCzP
IT Shopfloor Solutions Bosch offers solutions for automating manufacturing facilities from one source: the OPCON suite – a system the company itself has been using successfully for more than 15 years. The suite includes software modules that help flexibly control and monitor production data, quality data, and logistics processes according to the customer's specifications. Intuitive user interfaces support the work on the machine. Bosch Software Innovations contributed easy-to-use graphical controls to the IT Shopfloor Solutions. These make it possible for manufacturing specialists, even those without previous programming knowledge, to define rules; for example, to automatically recognize problems and resolve them in good time.
Bosch's contribution to the smart factory Bosch is also involved in the Smart Factory Demonstrator, which realizes the practical application of several core aspects of Industry 4.0. The demonstrator is an initiative launched by the German Research Center for Artificial Intelligence (DFKI) in Kaiserslautern, Germany, and is also on display. Bosch Rexroth collaborated on the demonstrator with automation manufacturers and developed one of the modules. Bosch Rexroth is also a member of SmartFactory KL e.V., a non-profit demonstration and research association in Europe. Details on the demonstrator: http://bit.ly/1IsIyff
Fuel cell system ready for series production Buderus will also be represented at the trade fair, featuring its power-generating heating system with highly efficient fuel-cell technology: the Logapower FC10. This electricity and heating system has an A++ rating for space heating in accordance with the EU's Energy Efficiency Directive. Available from early 2016, the Logapower FC10 is suitable for new and existing single-family homes and duplexes. The system supplies heat and electricity simultaneously through combined heat and power (CHP) generation. It achieves electrical efficiency of up to 45 percent and overall efficiency of up to 85 percent. For homeowners, this means they can save up to 1,300 euros on energy costs each year; what's more, by generating their own electricity, they become less dependent on the public power grid. And at the joint fuel-cell initiative booth, Buderus will be presenting the Logapower BZH192iT, a design study that demonstrates refinements to the successfully tested fuel cell featuring a new Titanium glass look with intuitive touchscreen interface.
Bosch KWK Systeme offers the latest in energy-efficient CHP plants and ORC (organic Rankine cycle) systems and will have a presence at the joint booth for decentralized power supply. Bosch's ORC solutions allow customers to use waste heat and generate electricity. They can be implemented anywhere with large volumes of unused waste heat.
Booth details: Motion drive and automation: hall 23, booth C19 Rexroth foundry technology: hall 5, booth D30 Industrial automation, “connected shopfloor solutions,” APAS family: hall 17, booth C42 Bosch Software Innovations and Bosch Rexroth: joint booth on connected industry and the digital factory: hall 7, booth E04 Bosch Thermotechnology hall 27, booth E51
Contact person for press inquiries: Thilo Resenhoeft, phone: +49 711 811-7088