1. 1 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Development process at BOSCH

2. 2 Bosch Group DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Hamdi Ayayüksel Mechanical Engineer Section Manager Development Dept. Investigation of Nozzle & Injector 11 years at BOSCH Introduction Murat Kocaçınar Mechanical Engineer Teamleader Development Dept. Off High Way Injector Projects and Design 10 years at BOSCH

3. 3 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Products Quality 0-km 2007 (ppm, year 2007) 0 CRI1/2 3,4 CRI3 1,9- Quality 0-km 2008 (ppm, year 2008) 0 CRI1/2 1,4 CRI3 3,1 - Quality 0-km 2009 (ppm, 05.10.2009) 0 CRI1/2 1,2 CRI3 1,612,5 Nozzle Production Volume in DS RBTR BaP CtP RzP RBTR BaP HoP DaeP CRI HDEV RBTR BaP

4. 4 Comparison between CRI2 and CRI3 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Pressure 200...1600 bar200... 2000 bar FeatureCRI2 CRI3 leakage * 2,5 l/h 0 l/h Needle velocityv open = 0,5 m/s v open = 0,8...1 m/s v close = 0,5 m/s v close = 0,8...1 m/s Mass of moving Parts: Needle:15,5 g Needle: 4,3 g Animation

5. 5 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Objectives of the PEP Standardized Procedures...  improve quality  reduce cost  save time  define a global process language  allow standard tool support  make processes measurable  increases transparency  ensure "best practice" always available  reduce "firefighting“  lessons learned  benchmark  improve efficiency!

6. 6 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Project Types and Project Categories What is a Development Project?  A project is a non-recurring task with a defined start, end, and result: Cost, quality, and schedule Someone responsible A sponsor A resource plan An increased coordination effort due to complex tasks  The following are not projects: Administrative tasks Daily and routine tasks Series supervision and comparable tasks

7. 7 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Customer Project Acquisition Project Acquisition projects are projects for acquisition and preparation of customer projects Customer projects are derived from platforms (with the goal to use preferred variants of the platform, or variants of the platform customized with a minimum of effort and at low cost) Project Types Platform Project Platform projects are basic developments with a high innovation level from which customer projects are derived Project Types and Project Categories

8. 8 Header of section DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Motivation of Design Application Variations -Start / Stop -Load Distribution -Ambient Conditions -Fuel Quality -Use Area Manufacturing technology -Serial Productivity -competitiveness -Cost Key Parameters -Exhaust Emission Laws -Noise -Fuel Combustion -Drive Comfort -Use Life -Endurance -Injection number

9. 9 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 1. Requirement Engineering 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

10. 10 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 1. Requirement Engineering Demands Offer -3000 bar -EURO 5 -0,5 m/sn V_open-close -2000 bar -EURO 4 -0,4 m/sn V_open-close

11. 11 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Product Range 1. Requirement Engineering

12. 12 1. Requirement Engineering DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Roadmap Common Rail System (CRS) for Passenger Car

13. 13 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 1. Requirement EngineeringPlatform Special types to be paid for separately (case-by-case decision) Platform core (preferred types) Acceptable platform variation Modular concept No quotation! Cost/ expen- diture Platform areas Degree of deviation from preferred types Cost/expenditure curve Feasibility Analysis

14. 14 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 1. Requirement Engineering Contract between Customer and Bosch  a project agreement is a commitment between two parties: The project start panel ( BOT)  Project manager Project manager  Subproject manager  covers the interests of all parties involved  is signed at project start and updated over project lifetime  describes the key data of the project (staff resources, budget, scope…)  defines the rights and obligations of the project manager  is the basis for the project

15. 15 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 2. Design Phase 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

16. 16 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Platform further functional upgrade improved performance Standard functionality with design adaptation Application (A) - Change to data record minor adaptations to system, e.g. nozzle variant Product innovation level Production process innovation level Plattorm development (PE) new product - new product area - no commitment to customers Acquisition/customer project First adaptation development (EE) for a customer First realization of a platform Adaptation development (AE) Platform development, further development First adaptation development Adaption development Application Project Categories 2. Design Phase

17. 17 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 2. Design Phase Benefit of Platform Development Bosch  Less effort in customer specific development  Consequently better basic development  Less variants, less modifications  Better protection of production processes  More efficient load on production Customer  Price advantage  Faster on the market with secured products  Quicker access to samples  Compliance with deadlines  Guaranteed function

18. 18 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Example From the Automotive Industry 2. Design Phase

19. 19 2. Design Phase DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Create Drawings/Models CAD Pro-E

20. 20 2. Design Phase DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Simulations. PATRAN 3D-CAD modeling program ABAQUS Program for the solution of static, dynamic problems. AMESim (Advanced Modeling Environment for Simulation of engineering systems) 3D CFD simulations cover ; Pressure distribution and resultant force Velocity distribution and resultant flow Cavitation zones FEM (Finite Elements Method) Hydraulic Simulation CFD (Comp. Fluid Dynamics)

21. 21 2. Design Phase DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Statistical Tolerance Analysis Create geometric model at CAD-System Create Tolerance model Calculation and Evaluation 123 At our department, the effect of drawing tolerances or measured value deviation due to production to product function and rate of first serial production can be calculated by using Statistical Tolerance Analysis.

22. 22 2. Design Phase DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Crank shaft axis Design method for spray geometry optimization nozzle spray piston glow plug Combustion bowl cylinder  Optimized location of the spray in relation to the glow plug for a good cold start behavior of the engine.  Best compromise of the elevation angle  Adjustment of the angle of the spray cone, number of sprays and lateral spray distribution for sufficient air access for each spray

23. 23 2. Design Phase DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Quality Tools Product FMEA (Failure Mode and Effect Analysis) The product FMEA analyzes the functions and properties of products as well their possible abnormalities towards the requirements and stipulates appropriate measures. Process FMEA (Failure Mode and Effect Analysis) The process FMEA analyzes the tasks and properties of processes as well their process factors and stipulates appropriate measures. DRBFM (Design Review Based on Failure Mode) DRBFM is a creative method accompanying the development cycle and at the same time a tool for discovering and solving problems without omissions. DRBFM resulted from the knowledge, that changes contain the highest failure potential, no matter whether products, systems or processes got changed for costs reasons, pressure to develop an innovative product or political requirements (e.g. laws). DRBFM is the method which prevents design failures and leads to the fact, that products maintain their high quality after a change. Pugh Concept EvaluationBasic Statistical Methods Project Preparation Concept Development Product and process development Serial production Pre- production SOP Invention Innovation 102345 Bosch Product development process (PEP)

24. 24 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 3. Prototype (Sample) Production 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

25. 25 3. Prototype (Sample) Production DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Sample Types: A Sample: Only Geometrical B Sample: Functional Definition C Sample: Validation (test) phase D Sample: Pre-serial Production

26. 26 3. Prototype (Sample) Production DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Cost Analysis: labour cost working hours return on investment tooling & consumption Infrastructure maintanance insurance energy Result:hourly rate (€)

27. 27 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 4. Testing 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

28. 28 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Project Validation Validation by CustomerBosch Internal Tests Basic Validation Engine Basic Validation Field Reliability Validation Field High Pressure Pulsation Test Load Collective Measurement Test Vibration test Nozzle Tip Temperature (Hardness test) Temperature Collective Test System endurance Test

29. 29 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Validation by Bosch High Pressure Pulsation Test The injector body has a permissible pressure P1 according to test target pressure P2 P1=1831 bar P2=1620 bar P1>P2 Successful test Load Collective Measurement Test Vibration test

30. 30 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Validation by Bosch Nozzle Tip Temperature (Hardness test) Temperature Collective Test Aim: During the runtime the highest temperature of the different parts of Injector are checked. System endurance Test Aim: Endurance of all the system parts are checked.

31. 31 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests EMI Curves Main Injection test pointsAdditional Injection test points VL 1450bar ~800µs EM 600bar ~630µs LL 300bar ~620µs VE2 1200bar ~240µs VE1 600bar ~290µs Maximum needle lift  end of balistic movement

32. 32 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests EVI Curves Multiple injection; Pressure 1450bar Energising time Pi 240µs Energising time Mi 800µs Pilot injection Main injection

33. 33 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests System Endurance Test (Aim: Endurance of all the system parts are checked.) HT = Hot Test : Increase of fuel temperature at pump inlet, 25h  from 70°C to 80°C 25h  from 80°C to 90°C IC = Intermediate Check: Control of injector function at hydraulic test bench according to the data sheet 0h IC-350hIC-700h IC-1000h IC-1500h 2000h HT Running time of system endurance test HT

34. 34 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests Overview of life time calculation City cycle Highway cycle pressure [bar] second

35. 35 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests Mechanical and Functional Tests Guidance clearance measurement Opening Pressure Spray geometry Valve bolt Valve plate Valve Lift Valve plate Valve bolt Throttle plate Valve Lift Measurement

36. 36 4. Testing DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Bosch Internal Tests Investigation/Reporting

37. 37 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 5. Pre-production / Release 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

38. 38 5. Pre-production / Release DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Fulfillment of Tech. Documents

39. 39 5. Pre-production / Release DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Q-Documents Production part approval process PPAP  Definition: Formal approval from the customer agreeing the parts meet or exceed their quality and performance requirements  Purpose: To confirm customer accepts the quality and performance of our parts made from the production manufacturing process, tools, etc. including suppliers.

40. 40 5. Pre-production / Release DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Submission Requirements

41. 41 5. Pre-production / Release DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Phase Release, Sales Assessment and Project Assessment  phase release : A phase release in general means the transition from one project phase to another project phase.  sales assessment Acquisition projects are subject to sales assessments. Sales assessments take place at the level of the overall project. During the sales assessment, the project start panel gives its approval to the release of the next project phase of the acquisition project.  project assessment Customer projects are subject to project assessments.. Project assessments take place at the level of the overall project and subproject. During the project assessment, the review panel gives its approval to the release of the next project phase of the customer project.

42. 42 5. Pre-production / Release DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Project Assessment Key Parameters Key Parameters; Status of Project (Project Management) Quality Tools Time Schedule Cost Supplier Risk Analysis Product Testing Process Development Engineering Change Request Project Preparation Concept Development Product and process development Serial production Pre- production SOP Invention Innovation 1 0 2 3 4 5 Quality Timing Cost

43. 43 DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The Product Development Process 6. Serial Production 4 Testing 2 Design Phase 5 Pre-production Release 6 Serial Production 3 Prototype (Sample) Production 1 Requirement Engineering

44. 44 6. Serial Production DS-PC/ENJ1-Bu | 07/10/2009 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Quantity of Production Project Steps PB0PB2PB3PB4PB5 3 5 50 SOP 500 500000 After serial Production the points below take into account; Ratio Projects are made. After Ratio Project all the changes are made by ECR special process. The Problems coming from Production are detected and decided to release according to SF(Special Release).