PASDEC PROFILE_10 MAY 2012
Transcription
PASDEC PROFILE_10 MAY 2012
COMPANY PROFILE Pasdec Automotive Technologies (Pty) Ltd May 2012 YOUR GLOBAL LOCAL PARTNER Company Profile Historical Perspective The company was established in Brits, North West Province, South Africa as Mega Electrical in 1969 to support the local South African vehicle manufacturing sector. During 1994 there was a merger between the Brits based Auto Cable Manufacturing and Port Elizabeth based Walro Automotive to form a joint venture company, Auto Cable Industries. In 1995 Delphi purchased a 51% equity in Auto Cable Industries due to pressure from the local O.E.M. to have a 1st tier harness supplier in South Africa to support the local car manufacturing industry. The need for such a requirement was due to the South African motor manufactures starting to conform to source plant requirements, thus potentially leading to a global exporting of vehicles from South Africa. This joint venture lasted until the end of 1997 when Delphi exited South Africa as well as various other joint ventures internationally. A decision was made within Delphi globally to either own the manufacturing in it’s totality or sell, however due to numerous problems within the global joint ventures, Delphi decided not to pursue the direction of outright purchase but rather to sell its equity in the business in South Africa. Auto Cable Industries was purchased 100% outright at the end of 1997 by the Malaysian based Pahang State Development Corporation (Pasdec), who then owned 84% of the shares on the JSE. Auto Cable Industries acquired Nippon (Pty) Ltd in 1998, a privately owned company supplying harnesses to Nissan South Africa. The company Nippon (Pty) Ltd, situated, in Ga-Rankuwa was then incorporated into Auto Cable Industries Brits plant in 2000. Subsequently and directly after this move the company was renamed Pasdec Automotive Technologies (Pty) Ltd. The current growth path, which saw the company not only survive the recession but also build a platform to expand, was given impetus in 2008 with awarding of the D22LCV, X11J, N11J & CR47, contracts by Nissan SA and Mercedes Benz respectively. In 2011 this growth was sustained when Pasdec was awarded the coveted UB90 contract for the Renault Sandero and the Nissan NP200 models. Further current undertakings awarded in 2011 and 2012 include the 283, 893. 868 and GCC projects for Nissan South Africa. In November 2011 Pasdec acquired a 30.87% shareholding in CRH Africa Automotive (Pty) Ltd, an established and respected automotive components supplier. Business Overview ˜ Established 40 years ago in 1969, Pasdec Automotive Technologies (Pty) Ltd leads in the supply and manufacture of automotive wiring harnesses to the OEM vehicle manufacturers in South Africa. ˜ Our dedicated manufacturing plants are purpose-built hence capacities are customized to accommodate both high volume production lines and lesser volume jobbing shop-type orders. The company has dedicated manufacturing and assembly plants, designed for current demand and future growth opportunities. ˜ Pasdec has recently invested in upgrading plants and equipment to assist towards increasing capacities and are now confident of exploring new opportunities with both local OEM’s and international markets. ˜ All products manufactured by Pasdec exceed international ISO requirement standards in terms of quality and applied technology further enhanced by “best global practice”, “continuous improvement programmes” and customer specific standards. 1 YOUR GLOBAL LOCAL PARTNER MISSION STATEMENT Our Goal The primary aim of the company is to design, manufacture and supply automotive wiring harnesses to its customers which are of superior quality and value. The philosophy of the company is to promote continuous improvements in quality and productivity with zero defects being our sustainable goal. Out product and service are important customer tools in the drive to achieve sustainable cost effective automotive wiring harnesses. To overcome the challenges we face from the fierce competition of other companies as well as the constant upward quality spiral we strive for, we have set our standards high. Thus by clearly and concisely communicating our principles and objectives as well as our customer requirements we believe we can achieve and maintain our goal – “TO BE THE BEST”. Our Vision To supply our customer with product and services which engenders the principles and viability for both parties through integrated partnerships. Our Mission £ To meet or exceed the requirements, expectations and needs of all our customers. £ To seek innovative, cost effective solutions to problems both locally and internationally. £ To supply products and services which are beneficial both functionally and financially to all our customers, both current and future, and to ourselves. £ To ensure that all our employees are qualified, trained and informed such that they shall be successful within their given areas of responsibility. £ To strive for continuous quality improvements within the company, the product, the service provided and the capabilities of all employees. FUTURE STRATEGY q To be focused and dedicated in all aspects of our operations. q To measure and continuously improve in respect of key performance indicators. q To implement and maintain internationally recognized management systems. q To establish and maintain a technological lead over our competitors, through accelerated change and through association and relationships with the worlds leading automotive wiring harness design manufacturers. q To develop one major relationship at a time 2 YOUR GLOBAL LOCAL PARTNER SHAREHOLDING STRUCTURE PASDEC RESOURCES SA LTD PASDEC HOLDINGS BERHAD 100% PAHANG OFF-SHORE (SDN) BHD 97% PASDEC RESOURCES SA LTD 70% 30.87% PASDEC AUTOMOTIVE TECHNOLOGIES (PTY) LTD MANAGEMENT & PUBLIC 3% P PATHER CAPITAL INVESTMENTS (PTY) LTD 30% CRH AFRICA AUTOMOTIVE (PTY) LTD 3 YOUR GLOBAL LOCAL PARTNER PASDEC AUTOMOTIVE TECHNOLOGIES (PTY) LTD BOARD OF DIRECTORS Name Designation Pasdec Automotive Technologies (Pty) Ltd Pasdec Resources SA Ltd CRH Africa Automotive (Pty) Ltd Remuneration Committee Internal Audit, Risk Management & Corporate Governance Committee Ethics Committee u u u u u u u u Audit Committee Dato’ Kamaruddin Bin Mohammed * Chairman u u Mr. Poovendhran Kevin Pather CEO & Managing Director u u Mr. Gabriel Mokgoko Director u Dato’ Majid Bin Mohamad* Director u u u Dato’ Abdul Rahim bin Mohd Ali* Director u u u Mr. Goh Song Han* Director u u u u u Mr. Mike Almond Company Secretary u u u u u u u * Malaysian 4 YOUR GLOBAL LOCAL PARTNER CURRENT PROJECTS Project UB 90 Renault Sandero and Nissan NP 200 (Annual Volume 22000 vehicles per year) Project X11C Nissan Tiida, X11J – Nissan Livina & N11J – Nissan X Gear (Annual Volume 7000 vehicles per year) Project 893 D22 Europe Export (Annual Volume 2800 vehicles per year) Project 868A D22 Africa Export (Annual Volume 15000 vehicles per year) Project 283 QW and D22 Local South African market (Annual Volume 9600 vehicles per year) CODE OF ETHICS By applying strict group policies and regular review meetings, the legal and ethical behaviour is maintained at a high level. The group uses the characteristics of good corporate governance as set out in the King II report, namely: n Discipline n Independence n Responsibility n Social responsibility n Transparency n Accountability n Fairness Management provides employees a platform through which, on an anonymous basis, they are able to report any suspected suspicious matters. Code of Ethics The Group has adopted a formal code of ethics, which forms the basis of the code of conduct for all employees. The Pasdec Group recognises the importance of the social and political stability of the community from which its workforce is drawn and contributes to people empowerment through holistic development, particularly in underprivileged communities. Educational development and HIV//Aids awareness and education forms part of the group’s strategic issues and receive priority at a high level within the divisions of the Group. 5 YOUR GLOBAL LOCAL PARTNER MANAGEMENT STRUCTURE Kevin Victor FINANCIAL MANAGER José Mike Almond GENERAL MANAGER STRATEGIC SERVICES Gielie Gielie Fourie Logistics Manager Logistics Coordinator Imports Fanie Phiri Margaret Hughes Senior Quality Assurance Manager HOD Warehouse & Distribution Pau Gualtiero 6 Kresen Moodly Quality Assurance Manager Quality Engineer Danie van Zyl Carol Raley Field Services Manager Engineering Services RNPO David Nthangeni Bertie Grobler Andreas Sarri Darren Hattingh YOUR GLOBAL LOCAL PARTNER LOCATION OF PLANTS Strategically located to meet the needs of our clients NISSAN NISSAN TOYOTA DAIMLER CHRYSLER CAPE TOWN PORT ELIZABETH LOCAL AND GLOBAL ACCREDITATIONS BY CUSTOMER Name of Company Accreditation - Local Accreditation - Global Nissan South Africa • ISO / TS 16949 • ASSES B4 Mercedes Benz SA • VDA 6.3 - A Rating • ISO / TS 16949 – • Green Status Process Verification System Toyota South Africa • ISO / TS 16949 • Toyota In House Quality System Approval • ISO / TS 16949 General Motors • ISO / TS 16949 • Supplier Evaluation Local Supplier Listing • ISO / TS 16949 • Supplier Evaluation– Global Supplier Listing Lotus • ISO / TS 16949 • ISO / TS 16949 • Approved Global Supplier 7 • ISO / TS 16949 • ASSES B4 • VDA 6.3 - A Rating • ISO / TS 16949 • Green Status Process Verification System YOUR GLOBAL LOCAL PARTNER B-BBEE LEVEL 4 ISO/TS 16949:2009 8a YOUR GLOBAL LOCAL PARTNER 8b YOUR GLOBAL LOCAL PARTNER QUALITY ASSURANCE OVERVIEW As per our Business Management System, quality is the responsibility of each employee to ensure the necessary controls are implemented and updated by continuous improvements. Each main Process Owner will take full responsibility for his processes ensuring the highest quality. The Quality Department’s main focus is to ensure that harnesses of superior quality are supplied to meet customers satisfaction and good customer relations is considered our number one priority. The philosophy of the Quality Department is to pursue never ending improvement in the supply of quality products and to support Pasdec’s business goals which is monitored by means of monthly indicators and through our Operational Manual activities. Internal Audits An audit program is compiled at the beginning of each year which can change during the year should the need arise. Process audits are now conducted more frequently and one can see the improvement not only from a housekeeping aspect, but also by the zero defects reported on the PPM reports from our customers. QA System Audits are done annually according to ISO T/S 16949 requirements. External verification audits are conducted annually by SABS to ensure that all procedures and processes meet current standards and requirements. Audits are conducted, necessary corrective actions taken, follow up completed and reported in the Management Review Meeting. CUSTOMER PPM STATUS Customer Care Customer complaints are handled immediately and reported to the responsible department whereby the necessary action is taken and feedback is then given to the customer. Customer visits 4 Nissan SA: Visits are conducted at least 3 times a week 4 Mercedes Benz SA: Visits are conducted at least 3 times a week PPM Reports 4 Nissan SA: Since 2003 Pasdec has achieved Nissan PPM targets 4 Mercedes Benz SA: Since 2004 Pasdec has achieved MBSA PPM targets Corrective and Preventative Action Corrective and Preventative action is taken on all issues that relate to quality products within Pasdec. This action is documented and actioned, so as to eliminate any subsequent quality problems. 9 YOUR GLOBAL LOCAL PARTNER QUALITY CONTROL LABORATORY To ensure superior quality products Pasdec utilises the latest technologies in the Quality Assurance Laboratory. The ELC Compact Lab has facilities to conduct: u Sectioning of terminals u Grinding and polishing of terminals u Etching of terminals Furthermore Pasdec utilises a computerized microscope linked to specialized software to measure terminal height, width and compression ratios. The laboratory is also utilized to do continuous process capabilities studies to ensure a quality final product is delivered to our customers. PATROL INSPECTION Patrol inspection is conducted from the cutting and crimping process until the final product. Daily attribute charts are used to report defects and when a defect occurs, it is immediately communicated to the operator and at the end of each shift, feedback to the line Supervisor and Managers at the end of Shift Forum meetings. Quality Patrol Inspectors use (100 % inspection) daily check reports on each production line to visually monitor any concern, if a concern, is identified immediate action is taken and recorded. This information is also fed back to the operator as well as to the end of shift forum meeting and a summary of defects are recorded on a weekly basis which is collated in the monthly report. Dock Audits (Internal Production Line Process Audits) are conducted by the Quality Engineering Department using check sheets. Any findings or observations are recorded and submitted to the responsible department to take action and a follow-up is conducted. RECENT ACHIEVEMENTS 8 2001 Nissan SA, “Supply Performance OE” Award 8 2001 Awarded the HS (Almera) Contract by Nissan SA 8 2002 Nissan SA - First supplier to Supply line side & sequence supply 8 2002 Mercedes Benz SA - Line side supplier to Colt 8 2002 / 3 Mercedes Benz SA / Toyota SA - Zero PPM 8 2002 Nissan SA, “Delivery Performance OE” 8 2003 Nissan SA zero PPM since August 2003 8 2004 Awarded the X11C (Tiida) Contract by Nissan SA 8 2005 Invested R11M into plant and equipment 8 2007 Awarded D22LCV Contract by Nissan SA 8 2008 Awarded the X11J Contract by Nissan SA 8 2008 Awarded the N11J Contract by Nissan SA 8 2008 Awarded the CR47 Contract by Mercedes Benz SA 8 2008 Invested ZAR22M into new projects 8 2011 Awarded the UB90 contract by Nissan SA 8 2011 Invested ZAR16M into new projects 8 2011 Commenced 283, 893, 868 & GCC projects for Nissan SA 8 2012 Investing ZAR23M into equipment & plant expansion YOUR GLOBAL LOCAL PARTNER ENGINERING OVERVIEW Technical Assistance Agreements Sumitomo Wiring Systems of Japan – Pasdec is the only company globally with whom SWS has a TAA. This agreement provides Pasdec with a prestigious position in the SA market given its close association with the leading EWH in the world. Thai Summit Harness of Thailand – Pasdec is privileged to be associated with the largest privately owned Automotive Group in South East Asia. PAT and TSH continuously seek other opportunities in the local SA market. Leoni Wiring Systems of France – Pasdec has achieved significant status by partnering jointly with Leoni in a TAA to manufacture the EWH for Renault UB90 models. This allows PAT the opportunity to create a road map into other European car manufacturers. Leoni is a strategic supplier to German car manufacturers such as BMW and Mercedes-Benz, including other European manufacturers such as Citroen, Peugeot etc. All Engineering and associated functions are done in line with the 5 stages of ANPQP and comprises of the following: Organization and Planning u A full pre contract logistics study is done (contract review / risk analysis / feasibility study) detailing the scope of product/process and the project duration with milestones defining customer timing. u This will include sub supplier selections where required, full top management support, and customer satisfaction based on customer feedback. u Quality and reliability plans/target are set for the project. Design Completion u FMEA and control plans are produced and or reviewed in line with contract requirements. u Full drawing analysis is done (CAD 2-D and hard copies obtained from customer) and design is verified, BOM’s are concluded and tooling verified. u 2-D wiring harness drawings are prepared, maintained, controlled and issued to the client u Prototype/S-lot build plans are confirmed and special product and process characteristics are defined within the scope of manufacturing to satisfy customer requirements and manufactured in-house. u Build and Test Boards are design and built according to customer supplied drawings. Extensive use of CAD ensures conformity to customer design. u A full logistics overview is done to determine delivery methods, i.e. JIT/Sequence/KANBAN or other method of supply to customer. This will include packaging standards/volumes and frequency of supply. u Regular development reviews are conducted in line with milestones and master schedule as well as product and processes and where required feedback is provided to customers. Off-Tool u Verification of supplied packaging standards in terms of supply method and frequency. u Process flow chart and finalization of plant layout are done where required. u Analysis of defects and comparisons/modifications done to FMEA/control plans to ensure defect prevention. u Finalization of process instructions as well as standard operating procedures. u Part inspection is conducted to validate off-tool products. YOUR GLOBAL LOCAL PARTNER ENGINERING OVERVIEW CONTD. Off-Process n Trail runs are conducted to ensure product and process capabilities and results are studied and evaluated. n ISIR is conducted to ensure parts manufactured are to customer specifications. n Further packaging evaluations are done to ensure conformity. n All components are entered onto IMDS and all testing is concluded according to customer supplied specifications, i.e. NDS/JIS. n Full development/design review is done to ensure product conformity. Post Start of Production n Further product and process audits are conducted to ensure variations are contained. n All activities towards ramp-up is conducted and verified in line with customer schedule and project handover to manufacturing is concluded. n Full development/design review is done to ensure product conformity and FMEA/control plans are updated. Pasdec uses the principles of concurrent engineering to reduce timing. The three (3) Auto Cad workbenches are used extensively to produce accurate and scaled build jig layouts for manufacturing as well as for product/process/plant layouts. The Engineering Department is well versed in VA/VE engineering and cost saving targets as well as man/machine/process developments. Extensive knowledge of the customer’s product ensures conformity as well as excellent QCD performance data and ultimately customer satisfaction. Engineering Engineering Manager Manager Departmental Management Departmental Management Development Process Development Process Project Management Project Management Customer and supplier Relationship Customer and supplier Relationship FMEA and Control Plan FMEA and Control Plan Senior Technician Senior Technician Senior Technician Senior Technician Senior Technician Senior Technician Drawing Analysis Prepare Quotes Design Layout (A/B) Customer Product Labour Time Process Instructions Customer Product Manufacture Documentation Control FMEA, Control Plan & Process Flow Drawing Analysis Drawing Analysis PrepareQuotes Quotes Prepare Design Layout (A/B) Customer Product Labour Time Process Instructions Customer Product Manufacture Documentation Control FMEA, Control Plan & Process Flow DrawingAnalysis Analysis Drawing PrepareQuotes Quotes Prepare Design Layout (A/B) Design Layout (A/B) Customer Product Product Labour LabourTime Time Proces s Instructions Process Instructions Customer Product Manufacture Manufacture Customer Product Documentation Control Documentation FMEA, ControlControl Plan FMEA, Control Plan & and Process Flow Process Flow Sample Build Foreman Sample Build Foreman st Supervise and build 1st prototype samples Sample SampleBuild Build Technician Technician Prepare components forfor sample build Prepare components sample build andand build sample build sample Parts Engineering Parts EngineeringWorks Works Foreman Foreman AssyBoard Verification Assy Board Verification MaterialPurchase Purchase(projects) (projects) Material Test Board Programming Test Board Programming (Level Change) PE PEW W Technicians Technicians Responsibilities: Assembly BoardManufacturing Manufacturing Assy/ /TTest est Board Assembly/ /Test TestBoard BoardMaintenance Maintenance AssemblY /Repairs / Obsolete/ Run out of Assembly / Test Boards Clerk Responsibilities: General Administration Administration General 12 Clerk Input ClerkData Data Input Responsibilities: andcomponents coding of Data Data input,input coding Components Manual Manual Documentation Documentation YOUR GLOBAL LOCAL PARTNER 14 YOUR GLOBAL LOCAL PARTNER Plant 1 – Brits (Assembly) Assembly: 5800m² Assembly moving lines: 6 x 8-board lines 8 x 10-board lines 3 x 12-borad lines 4 x 16-board lines Static lines: 7 x 8-board lines Tubing extrusion: Cincinnati Milacron (corr. Sleeving) 1 Samafor (PVC sleeving) 1 PLANT 2 – BRITS (CUT AND CRIMP, BATTERY CABLE AND EXTRUSION) Cut and crimp: 2500m² Cut and crimp: Komax Alpha 433S 1 Schleuniger CrimpCentre 60 2 Schleuniger CrimpCentre 70 2 Komax 40 5 Schleuniger Mega Strip 9600 1 Komax 41 4 Cable cut and strip 1 Komax 34 2 Megformat 1 Crimping machines 30 35T press 1 Joint splicing machines 12 15T press 2 Battery cable: PLANT 3 – EAST LONDON (DISTRIBUTION) Warehouse 700m² YOUR GLOBAL LOCAL PARTNER Plant 1: Assembly 15 YOUR GLOBAL LOCAL PARTNER 16 YOUR GLOBAL LOCAL PARTNER Plant 2: Cut & Crimp, Extrusion & Battery Cable 17 YOUR GLOBAL LOCAL PARTNER HR PHILOSOPHY & PRACTICE The HR philosophy is based on instilling a commitment to continuous achievement and work enjoyment for the individual as well as the organization through careful design and blending of a unique variety of learning, programmes. Taking care of human capital by developing their work and life skills significantly impacts key business objectives including productivity, customer service and profitability levels. To achieve this the company focus on: Integrated Performance Systems: Setting up detailed specific performance measurement metrics for key management. Coaching: Coaching people in the organization to perform better than ever and to broaden that achievement all the time. Organizational Genetics: Designing and aligning organizational people systems and structures to optimize the results and minimize waste and the resultant costs. Training training designed specifically to address our exact performance metrics and to skill our people to achieve the organization goals. TAA Training: In line with our Technical Assistance Agreement with KHP, it is by mutual consent that we have regular audits to ensure that we meet global standards. As the result Pasdec started an improvement plan to upgrade the operations, which has been successfully completed Employee Skills Development: Pasdec Automotive Technologies is characterized by a sophisticated, high-volume manufacturing process within a competitive and challenging environment. In addition Pasdec has to respond to competition from exports, export markets, on-going development as the result of changing customer needs and environmental issues this means that employees working at Pasdec Automotive require a range of skills and knowledge to help them respond to the exacting quality requirements and on-going change. The skills, knowledge and understanding required to participate effectively in the industry hence it is imperative that the company, ensures that its employees comply to a standard and to measure employees accordingly. Pasdec Automotive has committed itself to cultivate a culture within the company of continuous improvement. The company has since 2004 embarked on intensive training programs which were accredited by the Manufacturing, Engineering and Related Services education and training Association (Merseta). The training was specificly focused on the needs identified by the company as well as to assist employees to obtain a national formal qualification within the component manufacturing industry. The national certificate in automotive component manufacturing and assembly NQF level 2 can be obtained over a nine Month period. Three hundred and six employees employed by Pasdec have successfully completed this program. This achievement by Pasdec was the first in South Africa to qualify this number of learners. Due to the success of the program the company has offered employees the opportunity to advance to the NQF Level 3 training program. The Human Resources Legal Employment Compliance The company needs to comply with various laws governing labour within South Africa. The laws governing employment ranging from Basic conditions of employment act, Labour Relations act, Health safety and Environment matters, Employee Development and Skills act, corporate governance, Motor Industry Bargaining council regulations, Employment Equity Act to Social Responsibilities. 18 YOUR GLOBAL LOCAL PARTNER Skills Development is a Way of Life Pasdec's HR philosophy is based on instilling a commitment to continuous achievement and work enjoyment for the individual, as well as the organization through careful design and blending of a unique variety of learning programmes. Learnership Milestones u The programme commenced in April 2004 u By July 2007, 368 employees had advanced to NQF Level 2 (National Certificate: Automotive Component Manufacturing & Assembly) u Pasdec becomes the only company in South Africa with so many successful NQF Level 2 Learnerships u In April 2007, Pasdec prepares to move towards NQF Level 3 Learnerships at the Brits and East London plants u In the process, Pasdec becomes the first company in the North West Province to advance to Level 3 u Pasdec is often used by merSETA as a model site, referring other companies interested in establishing a Learnership Programme. u By 2011 Pasdec has passed 407 NQF 2 & 3 learnerships! u Pasdec embarked on a skills training project that 372 employees successfully completed in March 2011 u In 2012 383 people will be trained on an in-house skills programme developed in co-operation with merSETA. u With succession planning in mind, 17 people have been identified and placed in the 2012 Future Leadership programme in co-operation with Automotive Industry Development Centre and The Department of Trade and Industry. Employee Complement 2012 Category Direct Indirect Total % Permanent 181 71 252 47% Temps 166 26 192 36% Learners 48 12 60 11% 32 6% 536 100% Staff TOTAL 19 395 106 YOUR GLOBAL LOCAL PARTNER