Bendix Commercial Vehicle Systems LLC
VEHICLE SYSTEMS INTEGRATION
Bendix Capabilities
In-House Design • On-Site Validation • World Class Manufacturing
®
YOU CHOOSE.
Install this ONE module OR These 79 individual parts
Supply Chain
Eliminate 100 Part Numbers From
Your Materials System
Bendix will purchase, schedule, receive, inspect, inventory
and assemble all the components needed to build your
modules. Working with you, we will eliminate between
30 and 300 part numbers — and maybe even a few troubling
suppliers — from your system. That means you will
have more time to negotiate long term contracts with other
key suppliers and possibly eliminate poor performing
ones as well. All of this helps to strengthen your
competitive advantage.
By purchasing modules directly from Bendix, you can take
advantage of our significant and ongoing investments,
innovations and specialized professional capabilities...
capitalizing on benefits that are customarily very expensive
and time consuming to develop and maintain.
A Module Price That Is Often 5% Lower
Than Your Current Material Cost Alone
Our focus allows us to take significant material cost
out of your vehicle or chassis by using large- or small-scale
modules. Combined with our competitive conversion costs,
our price to you is typically below what you are currently
paying for material alone.
Our modules group consists of 20 seasoned professionals
focused on all facets of module design and production.
In addition, we are supported by a team of cross functional
Bendix representatives responsible for supporting the
design, validation, manufacture and shipment of modules to
a host of customers.
Immediate short-term financial payback and project
justification can be achieved. Labor savings, shop
floor space savings, reduction in warranty/scrap/rework
and reductions in inventory become “gravy” to the
payback equation.
Typical Cost Reductions Range
From $50,000 to $250,000 Per Year
Our focus on efficient design and manufacturing allows us to
offer yearly product innovations and/or cost reductions
to you. Although the amount per year varies by project,
each module agreement will contain measurable
productivity clauses to continually help you lower the cost
of your vehicle.
Bendix Commercial Vehicle Systems LLC
VEHICLE SYSTEMS INTEGRATION
BCM — Brake Control Module
for Low Cab Forward Vehicle
ICM — Integrated Control Module
Class 5-7 Heavy Truck
Production and Quality
Bendix Delivers On Time and In Sequence,
While Maintaining World-Class Quality
Problems with a Bendix module will not be part of your
morning production meetings. By fully testing sub-systems
within a module, we can help ensure product quality levels
remain at or above their historic levels of 5.0 sigma. In over
six years of production, over a quarter-million ICM-style
modules shipped to customers have reached OEM’s on
time and in sequence.
Our proactive attitude, formidable Six-Sigma infrastructure
— 250 Green Belts, 25 Black Belts and two Master Black
Belts* — and full company support continually improves our
modules offering.
Reclaim 5,000 ft2of Floor Space
Typically, sub-assembly stations, inventory presentation and
valve build-up areas require 5,000 ft2of valuable shop floor
space. When you source a module through Bendix, that
space can be reallocated to main production or prep’d
for model change. Plant expansions (est. $3/sq ft) and
machinery relocation (>$100,000) can be avoided, especially
during unfavorable industry cycles.
Bendix Quality: All The Way Down The Line
Bendix is driven by meticulous and exacting standards which
enable us to set new records for customer quality year
after year, including:
• Freightliner Masters of Quality Award Winner
(1999, 2002, 2003, 2004)
We have achieved world-class safety ratings measured in
TCIR and LWDCIR consecutively since 2003. And, in
addition, our facilities continue to earn significant quality
certifications such as:
• Elyria, OH: Certified ISO9001:2000 and ISO 14001
• Frankfort, KY; Huntington, IN; Acuña, MX:
Certified TS16949 and ISO 14001
EXAMPLE DAYS OF INVENTORY
Component-Based Modular
Manufacturing Manufacturing
In-transit 5.0 3.0
Components 14.0 .0
WIP .5 .0
Finished Goods 1.0 0.5
TOTAL DAYS 20.5 3.5
Dollars Material/unit $800 $800
Daily build rate 100 100
TOTAL INVENTORY $1,640,000 $280,000
INVENTORY REDUCTION ($1,360,000)
A solid benefit your Materials Manager will enjoy.
To date, we have shipped over 250,000 modules
and every one has been on time and in sequence.
Reduce Your Inventory By $1,360,000
BENDIX JIT DELIVERY PERFORMANCE
PPM
500
400
300
200
100
0
2005 2004 2003 2002 2001 2000
* Six-Sigma certificates as of 12/31/05.
Engineering
Product Engineers
Your Time Is Better Spent On Bigger Issues
All of the products you are responsible for have
challenges. Production issues, customer requests and cost
reductions usually rank high on the “annoying scale”. On the
other hand, those same problems seem to be more
challenging and fun when related to your “key” products.
Through modularization, we handle the annoying niche
problems so you can solve priority one product issues.
For example, as you walk the
production line, Jim, the torque
wrench guy, complains again
about the bolt hole alignment
problem. Last week you may
have given him an excuse
because you just didn’t have time
to deal with it. But since you have
a Bendix module, solving his
problem is more simple today.
You call the module engineers at Bendix and explain the
issue and how it can be fixed. We will take it from there. Jim’s
concern will be addressed while you go back to calculating
the new steeper wheel cut angle you just helped develop.
Having your “staff” of Bendix engineers comes in handy.
All are part of a company that has been a pioneer in
the heavy vehicle industry for over 75 years with over
130 active patents.
Engineering Managers
Core System Focus
“Why did you ask me to list projects that are important to
work on next year and then deny the additional headcount?
This is so frustrating.”
With a Bendix module, the “additional staff” you need is
already on staff. Shift your staff’s time from “annoying” to
“core” to increase your total vehicle innovation. Your team
can now complete more projects that previously would
have slipped below the cut line. We innovate the module,
you innovate the core. Bendix has implemented over 40
innovations in a five year period for our current customers.
As systems are redesigned and integrated into a module,
some interesting things happen. First, a common structure
replaces the “bracket on bracket” approach. Second,
individual components are combined into smarter parts that
reduce fittings and wire harness complexity. Third, a module can
be tested at the system level. This ensures functional, electrical,
air and other systems. You buy systems, not components. The
impact on cost, quality and innovation is dramatic.
Current and Support
In the middle of the year, your biggest fleet calls. Another
vehicle nameplate is offering an A/T shifter on their work trucks
and his drivers love it. This is not available on your vehicles. He
wants to know how long it will take you to make it available.
How you answer this customer depends, in part, on the
strategic suppliers you currently have in the fold.
DIFFERENTIATION ROAD WORTHINESS
•
Compliance (NTHSA / FMVSS )
•
EPA regulations
•
Certification testing
•
Validation testing
•
Turning radius
•
Driver visibility
•
Operating costs
•
Fleet options
•
Style
•
Interior trim
•
Wheelbase configurations
•
NVH (noise, vibration,
harshness)
•
Ergonomics
•
Crashworthiness (safety)
•
Ingress/egress
•
Supplier-related component
issues (defective seals, etc.)
•
Material changes
•
Vendor problems and resulting
vendor transitions
•
Supply base cost reductions
•
Drawing changes and updates
•
Part number consolidation
and management
•
Miscellaneous manufacturing
problems
•
Various "what if" exercises
•
Wire harnesses and glove
box lighting design
•
Brackets and bracket
placement
•
Component testing
CORE PROJECTS
~15
NON-CORE PROJECTS
~500
MISCELLANEOUS
WHERE DO YOU FOCUS YOUR TIME?
vs.
%
%
SHIFT YOUR FOCUS
Strategic Management
Oversee Unparalleled Long-Term
Corporate Flexibility
Modularizing your vehicles gives you unprecedented
flexibility to deal with difficult market conditions such as:
• New engine regulations in 2007 and beyond
• Pass-car technology migration
• Aggressive competitor pricing
Additional Flexibility:
• Changing fixed costs to variable
• Sharing / amortizing capital investment
• Leveraging supplier sunk investments
• Reallocating labor
• Reducing on-site inventory
• Increased leverage with core suppliers
• Increased buffering for demand changes
• Multi-discipline problem solving ability
If you decided to build modules in-house, your investment
would be $1.5m. Let us help you avoid this.
Gain Access To Special Skill Sets Not
Currently In-House
Our modules program allows you to gain access to our
specialized skills, tooling, processes and equipment.
Feature-based ordering, cumulative buying power, on-site
testing and in-house design are just a few. Since Bendix is
part of the Knorr-Bremse Group — with strategic locations in
over 20 countries worldwide — your regional vehicle
concerns can be addressed “locally.”
It doesn’t matter whether you compete on cost, profitable
options, responsiveness or perceived quality. Incorporating
modules into your building brings a more competitive
cost structure that helps drive profits even before you sell
additional vehicles.
Avoid Expensive Plant Expansions,
Equipment Relocation and Costly
Capital Investments
Plant expansions can easily cost $3.00 per square foot. When
you consider the added fixed burden that approach brings,
you understand why we advocate a different approach.
Incorporating a Bendix module can free up 5,000 square feet
(or more) of shop floor space. This also comes in handy for
the next new model equipment location.
OEM Marketing and Sales
Upselling Options and Joint Marketing
Boost Your Sales
Think about enhancing your competitive advantage by
offering new options to the marketplace not currently on
your vehicles. Consider how much additional profit would
options such as an: A/T shifter, adjustable pedals or
telescoping steering column could bring to your bottom
line. Once these options (or any other you may select)
are released on your module, Bendix will support the
promotional efforts of your sales force to enhance
pull-through and upselling. Get the established Bendix
sales force to work for you.
A Lower Cost Structure Allows More Price
Flexibility For Promotions
With a material cost reduction, labor cost reduction and
inventory savings, you will be in a much better position to
battle in the marketplace. Whether you want to gain market
share or defend what you have, modularization will offer you
the price flexibility that can make the difference. Have you
ever lost a bid for ~$50/vehicle? Find that $50 savings
in modules.
– New vehicle launch – Aggressive cost downs
– New chassis launch – Major inventory tasks
– Major chassis redesign – Major quality initiatives
– Production line retooling – Drive for technology
– Shop floor constraints – Supplier base reduction
WHEN YOU SHOULD CONSIDER MODULES
Your No-Risk/No Obligation Offer
Can a module really lower your vehicle cost AND increase its
innovation at the same time? Can a module really increase
your vehicle’s quality AND reduce warranty almost overnight?
Let us answer your questions with our no-risk, no-obligation
offer. We will perform a detailed analysis of your existing
module and provide you with our findings in four to six
weeks. The conclusions will, no doubt, be of interest to a
number of cross functional teams within your organization,
including purchasing, engineering, production, sales and
upper management.
Just follow these four simple steps and see for yourself.
1. Define a high-volume “track” vehicle.
2. Provide us with a module built in-house that fits on that
track vehicle.
3. Be willing to answer questions that may surface during
the analysis we perform.
4. Be willing to meet with us in four to six weeks to review
the benefits we uncover.
ENHANCE YOUR COMPETITIVE EDGE WITH A BENDIX MODULE.
TO LEARN MORE, CONTACT YOUR BENDIX ACCOUNT MANAGER
OR CALL TJ THOMAS, AT 1-800-247-2725.
Bendix Commercial Vehicle Systems LLC • 901 Cleveland Street • Elyria, OH 44035 • 1-800-247-2725 • www.bendix.com
BW2548 ©2006 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • All Rights Reserved • Printed in USA
®
ICM — Integrated Control Module
RAVM — Rear Axle
Valve Module
BCM — Brake
Control Module
(floor mount pedals)
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