INOVAR-AUTO AND INNOVATION MANAGEMENT
INOVAR-AUTO AND INNOVATION MANAGEMENT How to get the expected results on time Ricardo Simões de Abreu Global VP Engine Systems and components Product Development MAHLE Metal Leve S.A. © MAHLE Inovar-Auto and Innovation Management Research and Development Centers Stuttgart Detroit (Farmington Hills) Northampton Tokyo (Okegawa) 1998 Shanghai Rugby 2002 2004 Tokyo (Kawagoe) 2004 São Paulo (Jundiaí) 2006 2001 2008 2 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Jundiaí Tech Center The Technological Center in Jundiaí , result of an investment of R$ 87 millions, is the largest center for engine components development in all Latin America. 3 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Common points from countries recognized as innovative Innovation is triggered by necessity (legislations) or opportunity to improve competitiveness (market demands). Innovation is the part of an appropriated environment. The innovation culture is part of the society. The academy aims to bring products to the market and not only generates new knowledge. The government support is mandatory to leverage innovation. Innovation today must be quick, but it can not be done in a hurry. It must be planned well in advance and executed with discipline. 4 The risks and long term returns to assure future developments must be part of the strategy. MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Innovation is the part of an appropriated environment The innovation culture is part of the society Governmental Biofuel Programs – 5 Biodiesel Test Program B5 & B20 Partnerships – Friction reduction thru oil lube developments – Oil oxidation in flex fuel engines Technical Committees – Energy Efficiency Committee – Renewable Fuels for Diesel Engines – Engine Powertrain standards – Turbocharger standards – Emission in Passengers Cars and Diesel Engines MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management The academy aims to bring products to the market and not only generates new knowledge Consortium about tribology to future flex fueled engines Consortium about lubrication in internal combustion engines 6 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management The government support is mandatory to leverage innovation 7 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Inovar-Auto Objectives Increase the regional content measured by the acquisition volume of parts Ensure R&D investments (innovation) Create basis to automotive engineering with self life and capability, not just to apply or Increase the spending on Engineering and look for existing technologies, but creating Basic Industrial Technology new technologies, generating value and Increase the vehicles energetic efficiency: intellectual property. vehicle labeling (INMETRO) and CO2 emissions reduction COMPETITIVE ADVANTAGE BY ACHIEVING MORE THAN THE BASIC LEVEL 8 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management IPI Incentives (+2p.p IPI) – Fuel Efficiency Previous INOVAR - AUTO Since Dec 2011, cars with less than 65% of parts produced in Mercosur and Mexico are charged 30 p.p. additional IPI (between 37% and 55%) Exemption of the 30 p.p. for cars that use more regional produced parts and have minimum 8 out of 12 manufacturing steps made locally (ex: stamping, welding, chassis assy.). Increasing to 10 in 2017 No incentives for fuel efficiency. Starting 2017 till 2020, estimated national fleet average must show 12% reduction. The individual targets depend on vehicle weight and today efficiency level. BONUS INCENTIVES - If improvement in fuel economy is 15% an additional 1 p.p. IPI is deduced. For 18% reduction another 1 p.p. IPI is reduced. 9 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Available and Future Technologies 0% CO2 -10% CO2 -20% CO2 Combination of technologies is possible! Downsizing (single turbo) GDI General optimization GDI + EGR* (hom)* (lean) (Friction & Cooling) Fully Variable Valvetrain VVT/VVL* EPS * StartStop CO2 reduction potential Inovar-Auto *) -1% IPI -2% IPI Available Available in Brazil outside Brazil VVT: Variable Valve Timing VVL: Variable Valve Lift GDI (hom): homogeneous Gasoline Direct Injection EGR: Exhaust Gas Recirculation EPS: Electric Power Steering (direct contribution to powertrain efficiency due to omission of hydraulic pump) Source: The Boston Consulting Group 10 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Available and Future Technologies 0% CO2 -10% CO2 -20% CO2 Lowest cost with available technologies Downsizing (single turbo) GDI +Ethanol (hom)* General optimization (Friction & Cooling) StartStop?! Ca. 65% downsizing cost Fully Variable Valvetrain Ethanol as technology booster… VVT/VVL* •EPS Higher efficiency, lower cost more km per MJ Start•*Neutral well-to-wheel CO2 balance Stop • Renewable Inovar-Auto *) CO22reduction reductionpotential potential CO Available Ethanol Available in Brazil application outside Brazil GDI (hom): homogeneous Gasoline Direct Injection Source: The Boston Consulting Group + FEV&RWTH Aachen -1% IPI -2% IPI 11 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management IPI Incentives (one p.p. IPI from 2013 to 2017) R&D (Innovation) I. Basic research comprising activities to develop knowledge for new phenomena understanding, aiming development of products, processes or innovative systems; II. Applied research, comprising activities to develop knowledge, aiming improvement or development of products, processes and systems; III. Experimental development, comprising activities based on existing knowledge, aiming confirmation or demonstration of technical or functional viability of new products, processes, systems and services or, a clear improvement of already produced or established ones; IV. Technical support services, namely the ones considered essential to the implementation and maintenance of the facilities or equipments exclusively dedicated to the execution of the research projects, development or technological innovation, as well as related human resources development, directly related to the activities cited in previous items I, II and III. 12 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management 3rd Phase Innovation today must be quick, but it can not be done in a hurry Ideation Tech Incubation 2nd Phase University Processes Product Tech Incubation Product Ideation 1st Phase Product Adaptation VA/VE Adaptation Process Processes Processes Processes Application 0 1 2 3 4 5 6 7 8 Execution Time (years) 13 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management 1st Phase examples: Specific technologies adaptation Pendulous Oil pump 1º Ring On demand oil flow to increase fuel economy Piston Abrasive wear and dirt insensitiveness 2º Ring Many possible adjustments Oil ring Whole life high volumetric efficiency (>92%) Silent operation Fuel consumption reduction of 1 - 3% Pin Connecting rod Bearings PCU optimization: up to 2% Fuel economy 14 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management 2nd Phase example: Polymeric bearing START STOP Fuel consumption reduction of up to 3,5% Stop-start conditions will increase wear on main bearings Wear Evaluation After 100,000 stop-start cycles Front main bearings must absorb combustion loads and extremely high belt loads often acting in opposite directions Depending on the belt load vector, wear can be seen on lower shell or upper shell Al bimetal Al bimetal + polymer After 100,000 start/stop cycles the wear of the Polymeric bearings is 10 times lower Effect of Belt Load on Front Main Bearing 15 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management 3rd Phase examples: Advanced technologies Nanotechnology: With nanometric layers, its is possible to build a superior performance coating in durability combined with low friction Polymers: High resistance to fatigue with wear resistance and friction reduction Ceramic: Protection technology for corrosion and wear and low friction through new technologies 16 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Innovation must be planned well in advance and executed with discipline Keep FOCUS Do the right THINGS Do the things RIGHT Reduce TIME-TO-MARKET Customer DG 0 Approval 17 DG 1 Concept Develop. MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 DG 2 Concept Validation DG 3 Industrialization Process DG 4 Post Launch © MAHLE Inovar-Auto and Innovation Management The risks and long term returns must be accepted Sales 5 New Products Launched Start up R&D Projects 37 New projects in R&D Idea Allocation 106 New ideas 76% of the new products launched in the last 3 years sold to least one commercial application 18 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Assure future developments must be part of the strategy Increase of patent numbers in USA Patent cases filed Patents granted China intends to increase the number of patents to 1,5 mio/year until 2020. Internals Externals Total Patents applied in Brazil (PCT): 2011 = 31.000 2012 = 37.000 PCT (Patent Committee Treaty) 19 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Inovar-Auto and Innovation Management Conclusion Compared to international experience, Inovar-Auto is first step in the right direction. Long term targets and rules are necessary to trigger innovation. Brazilian experience with bio fuels must be part of the strategy to boost competitive advantage. 20 MAHLE Metal Leve S.A., Ricardo Simões de Abreu, October'13 © MAHLE Thank you! ricardo.abreu@br.mahle.com 21 © MAHLE
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