Production

Global production with BPS
Seeking out best practice methods
JIS manages just-in-sequence production
MTM creates an optimum work environment
Aluminum and plastic dominate production

Germany	Berga, Freiberg, Kirchberg, Kornwestheim, Mühlacker, Mylau, Neustadt/Donau, Pforzheim, Reichenbach, St. Georgen, Stuttgart, Vaihingen/Enz
France	Hambach, Rouffach
Spain	Montblanc 1, Montblanc 2
Czech Republik	Holysov, Mnichovo Hradiste
USA	Charleston, Dayton, Fort Worth, Grand Rapids
Brasil	Arujá
South Afrika	Durban, Port Elizabeth, Pretoria

Global production with BPS
Behr produces its components, modules, and systems for air conditioning and engine cooling at 22 locations around the globe. In production, standards are necessary for attaining top quality and an optimal price/performance ratio. For this purpose, Behr introduced the company-wide Behr production system BPS. With BPS, we can identify, standardize, and implement our methods under “best practices” aspects. These findings are entered into the BPS database, which contains uniform, mandatory applications for clearly defined standards and methods that are valid for all plants and product lines. With BPS, Behr has a platform for exchanging experiences, so that improvements can be made as quickly and cost-efficiently as possible. BPS is also closely linked with the Behr Development System (BDS) associated with research and development Global development network . Our mandatory standards and methods are documented in the Behr Management System (BMS). Wherever in the world we build a new location, employees can access all relevant Behr standards via the BMS manual.

Seeking out best practice methods
With the introduction of BPS, Behr has defined seven types of waste: overproduction, storage, waiting times, scrap, movement, shipping, and processing. In short, best practice means that the new solution must have a clearly positive effect on one or more of these types of waste, and will thus save costs. It is important that we find these solutions in the course of day-to-day work, which is why all employees contribute to BPS. If, for example, someone in Arujá, Brazil, or Wuhan, China, has a brilliant idea, their suggestion is reported to the BPS coordinator. Working with the person who had the idea, the suggestion for improvement is described and, if possible, documented with images. If the BPS champion accepts the idea after it has been processed and tested, this best practice method becomes part of the globally accessible BPS database. Our BehrOxal^® coating process is one example of a best practice idea. With BehrOxal^®, we can coat evaporators and other aluminum components in an environmentally-friendly manner without any chrome.

JIS manages just-in-sequence production
Logistics is a key production factor, as it has an effect on almost every type of waste. Behr uses just-in-sequence (JIS) delivery, which is a step up from just-in-time (JIT). With JIS, we can guarantee our customers that their modules will be delivered in sequence. This means that we load directly from our production line onto trucks, then deliver the modules to our customer's assembly line - in exactly the right sequence. The advantages of JIS are that we do not require shipping warehouses and our customers do not need an incoming goods warehouse.

MTM creates an optimum work environment
At Behr, MTM stands for Methods Time Management and is a procedure for designing workplaces ergonomically and economically. MTM aims to improve production and efficiently organize production processes. For this purpose, we pay attention to repetitive motions in manual tasks in order to recognize and avoid unnecessary movements. Grab distances can be shortened, for example, or the work steps in an assembly line evenly distributed among employees. MTM does not begin with production planning, but already during the acquisition phase for a project - which is long before production starts. We examine processes and workplaces early on, as well as the product.

Aluminum and plastic dominate production
We make sure that the materials and workmanship of our components, modules, and systems are of the highest quality. Behr uses the latest process engineering techniques for its air conditioning and engine cooling products. Aluminum is the main material used for condensers and evaporators in HVAC units. In cooling modules, it is used for charge air coolers, oil coolers, radiators, and other engine cooling components. In addition to aluminum, top-quality plastics are being used more and more, as well. Modern, temperature-resistant plastics can be used in almost every part of the engine today.Because they are so flexible, plastics are ideal for developing designs for control units, blowers, and air ducting systems. For plastic components, Behr uses the so-called MuCell process (microcellular foaming), an injection molding technique with which we can produce all of the housing parts for an HVAC unit. MuCell’s special trick is that a gas - either nitrogen or carbon dioxide - is injected into the molten plastic. When the gas expands, microscopic cells are formed in the plastic, which compensate for volume reduction of the molten plastic during cooling. This foaming is what gives the product its form. This process saves on material and ensures that components and modules are noticeably lighter than those produced using conventional injection molding techniques.