Upload
vonhan
View
230
Download
4
Embed Size (px)
Citation preview
Subaru of Indiana Automotive, Inc.
Where Our Associates Are Focused On Quality,
Safety and Environmental Stewardship
Subaru of Indiana Automotive, Inc.
I M P R E Z A
SIA Model Lineup
Training & Reception Center
Child Development Center
Recreation Center
Subaru of Indiana On-Site Facilities
Health & Wellness Center
Subaru of Indiana Plant Map
N5
N54
N13 Body CMM CMM O R/R
Room Room
R/R A-Line
Assembly
N55 Service Coil
Engine O Parts Storage
Maint. Sub-Assembly Storage
R/R A-Line A-Line
Engine Manufacturing Assembly Assembly Kaizen
Warehouse Warehouse E Press
K Kaizen EDM IPC B-Line Assembly Pit
W23 A-Line A-Line R/R
Assembly Assembly
B-Line Forklift
Engine Forklift Batteries Pilot Cage O Cage R/R
Assy Charging Forklift B-Line Assembly
Batteries
B-Line Assembly
B-Line Assembly Die Storage
A-Line Assy E
O R/R
T/F B Assy Layout A-Line Die Storage
Tire Bay Kaizen T/F R/R B-Line Enclosure Line Assembly R/R O
T/F-A Maint B Assy IPC A-Line Enclosure Line TY-1
Pilot Bumper Tool M en's
Room B-Line Metal Finish Line A-Line Metal Finish Line Storage & Die Lockers
T/F-B DS-1 DS-2
Pilot Training Office Office R/R
Room Room W Locker
Paint Mix
Paint Paint (Mezz)
Touch Touch R/R Cafeteria R/R Pretreatment Line E3
-up -up
PVC Booth Electro Deposition Chiller
R/R Loc. Storage
CCR R/R Surfacer Booth
R/R Tu-Tone Booth
R/R
Top Coat B
CCTV
QE/ E DI Water Large Waste Water Cleaning
VES S14 M Paint Storage Paint Mix Room Sludge Pit Treatment #1 Room
S15 S13 S12 S11 S10 Dock S9 S8 S7 S3 Dock S2 S1
T/F Circle S5 S4
Repair Drive R/R
Paint #1 Receiving
T/F Drizzle Receiving
Repair Tester Paint Maintenance Paint Shop Kaizen
Flags
FTZ-1
PS2 Tunnel
Ram
pRam
pR
amp
R/R
MaintBailer W
iese
Kaizen G-Press
Pilot
F-Press
(9000 Ton)
SQA BL-2 (500 Ton)
Testing
Trans. Mating
R/R
D Press
(3500 Ton) Die Storage
Maint
Maint
C Press
(3500 Ton)
Office
R/R
Assy
B-Line Door Line
Office
B-Line Assy
A-Line Chassis 2
A-Line Trim 2
B-Line Chassis 2
B-Line Chassis 1
B-Line Trim 1
B Press
(4500 Ton)
BL-1 (500 Ton)
IBMS
Mezzanine
HazMat Storage
A Press
(2700 Ton)
Cage
R/R
B-Line IPC Inspect
MIS
B-Line IPC Repair
R/R
Die Wash
A-Line Final
A-Line Trim 1
B-Line Final
B-Line Trim 3
B-Line Trim 2
Office
B-Line Sub Assy
Pilot RoomA-Line Final Insp
B-Line Final Insp
Rm
115
A-Line Door Line
Computer
Room
Rm
110
MIS
Med
R/R
Security Drive
Door
Atrium
Lobby
Sec
A-Line Bumper Paint
Top Coat A
R/R
Engine Assembly
Water Test
IPC Tester Line
Reliability Room
ATM
Administration Area
Office
A-Line Assembly
.
IJ-1
IJ-2
IJ-3
.
A-Line Assembly
A-Line Assem
bly
.
.
B-Line Assembly
B-Line Bumper Paint
B-Line Assembly
B-Line Assembly
.
.
Chiller Area
C
ChillerArea
B
Chiller Area
A
Chiller
Area D
Engine
Test
As of
12/13/20166
FACILITY LAYOUT
StampingBody
Paint
Trim & Final
Materials StorageEngine
Paint 2
Materials Storage
(Under Construction)
Office
Number of Associates: 5565 (includes variable workforce)
Staffing:Administrative: 775 (14%)
Production: 4790 (86%)
Production Shifts:
1st Shift: 6:00a.m. – 2:30p.m.
2nd Shift: 4:30p.m. – 1:00a.m.
(Friday: 3:30p.m. – 12:00a.m.)
Site Area: 820 acres (excluding easement and right of ways)
Improved Area: 620 acres
Building Area (Foot Print): 3,341,399 square feet
Floor Space ( with Mezzanine and Penthouse): 4,419,093 square feet
Conveyors: 16.85 miles
Current Production Capacity:
(Units/month with current manning; based on an eight hour-
per-shift schedule)
23,305 (Subaru 15,805; Camry 7,500)
Allowable Production Volume Under SIA’s Air Operating Permit: 450,000 units
As of October 31, 2016
SIA Operation / Facility Overview
SIA Full-Time Employment
0.5
1
1.5
2
2.5
3
3.5
4
Subaru Market Share Momentum
2011201020092008200720062005 2012 2013 2014
3.9%
2015 2016
6193 63605725 5425
38764294
6137
5267 49974526 4496 4279
62735688
4762
5753
4471 4612
5549 5576 5264 5023 52055792
60276134
11,296
12,602
14,11214,749
11,32311,317
12,48412,51512,370
10,91210,82911,082
15,11014,710
13,050
16,041
11,166
11,857
14,099
14,278
12,39613,413
14,676
17,331
16,965
17,971
13 9 30 9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
17,502
18,971
19,86720,183
15,19915,611
18,621
17,78217,367
15,43815,32515,361
21,38320,398
17,812
21,794
15,63716,469
19,64819,854
17,66018,436
19,881
23,123
22,992
24,105
0
5000
10000
15000
20000
25000Sep-14
Oct-14
Nov-14
Dec-14
Jan-15
Feb-15
Mar-15
Apr-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
US Domestic Sales of SIA-Built Vehicles
Total
Outback
Legacy
Tribeca
Confidential 11subaru-global.com
Start of new paint shop production:
February 29, 2016
Prior SIA air permit limit: 310,000 units
SIA air permit limit after new paint shop started operations: 450,000 units
SIA’s Paint Shop Expansion
Confidential 12subaru-global.com
Quality
0.87
8.10 7.70 7.60 7.306.70
10.20
5.77
4.34 4.16
9.00
11.709.70
6.60
4.20 3.604.10
2.803.50
1.96 2.061.961.54
0.94 0.680.87 0.90
22.70 22.70
21.00
14.80
13.30
10.20 10.40 10.20
6.80
7.30 7.206.70
12.2011.40
29.10 29.20 28.60
18.40
16.10
13.50
7.60
6.405.91
4.914.914.51
0
5
10
15
20
25
30
35
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
SIA
National Average
Transplant Average
OSHA Frequency Comparison 1999-2016Incident Rate
*Incident Rate (IR): Amount of injuries that occur for every 100 Associates
ISO Certification
1st auto assembly plant in the U.S. to achieve ISO 9001 Certification (March 17, 1995)1st auto assembly plant in the U.S. to achieve ISO 14001 Certification (November 10, 1998)1st auto assembly plant in the U.S. to achieve ISO 50001 Certification (May 28, 2012)
SIA Environmental Milestones & Awards
1994 - 1st Auto Assembly Plant to Ban All Indoor Smoking
1998 – 1st Auto Assembly Plant in U.S. to be ISO 14001 Certified
2003 – 1st Auto Assembly Plant in U.S. to be Designated a Backyard Wildlife Habitat by the NWF
2003 – Indiana Governor’s Award for Environmental Excellence (Recycling/Reuse)
2004 – 1st Auto Assembly Plant in the U.S. to Reach Zero Landfill
2006 – Indiana Governor’s Award for Environmental Excellence (Five Years Continuous Improvement)
2007 – EPA WasteWise Gold Achievement Award for Industrial Recycling
2008 – EPA WasteWise Gold Achievement Award for Climate Change
2009 – EPA WasteWise Gold Achievement Award for Community Involvement
2011 – Urban Wheel Award for Greenest Automaker in America
2011 – American Manufacturing Strategies Award for Greenest Manufacturing Plant in America
2012 – 1st Auto Assembly Plant in U.S. to be ISO 50001 Certified
2014 – Indiana Governor’s Award for Environmental Excellence (Energy/Renewable Resources)
2013 – Campbell Institute/Stewardship Action Council 2013 Innovation Challenge Award for Zero Waste
Corporate Social Responsibility
“People dig the idea of buying a car that has been built in a zero-landfi9ll plant, nestled in the center of an 832-acre Backyard Wildlife Habitat.”
-cheatsheet.com, August 1, 2016
“Subaru of Indiana isn’t satisfied with just keeping its own operations lean, clean, and green, but is also a leader in teaching other companies how to get to zero landfill in their business,…”
-TreeHugger.com, May 14, 2015
“Zero waste makes the plant a model not only for other carmakers – GM, Honda and Volkswagen have all made strides – but for other industries as well.”
-takepart.com, December 30, 2013
“SIA has a mountain of compost and the occasional coyote skittering through the surrounding 832 acres of woodland. Step inside,though, and you’ll discover why this might be the most exemplary car factory in America.”
-Bloomberg Businessweek, June 6-June 12, 2011
“It’s (SIA) as much a biosphere reserve as an automotive plant.”-Los Angeles Times, April 13, 2011
"At the Subaru of Indiana plant, the workers are constantly devising and revising green initiatives. The factory has dramatically reduced waste per vehicle and puts no garbage in landfills.“
-Wall Street Journal, March 16, 2009
“At SIA…being green can save some real green.”-USA Today, February 19, 2008
“Drive up to Subaru of Indiana Automotive and you’d swear you were entering a nature park.”-Edmunds.com, February 13, 2008
www.subaru-sia.com