Analysis of Industrial Plant Relocation: Bosch Fuel Delivery Module Study Case

This paper presents an in-depth analysis of Bosch's strategic relocation initiative for the production of the Fuel Delivery Module (FDM), based on an internship conducted at Robert Bosch GmbH's Italian branch in Turin from November 2023 to March 2024. The internship, undertaken in the role of a Technical Sales and Project Management Engineer, focused on managing both the commercial and technical aspects of Bosch products, with a specific emphasis on the FDM and the Diagnose Module Tank Leakage. The primary objective of this thesis is to examine Bosch's relocation process for producing the fuel delivery module, a product that has been in production since 2001, entailing the transfer of the FDM production line from Munich, Germany, to Budweis, Czech Republic. Working within the Powertrain Solutions division, primarily catering to Stellantis as client, the internship commenced when approximately 75% of the relocation activities were completed, with a focused effort on product validation. Close collaboration with the Bosch team at the Budweis plant proved instrumental, necessitating interaction with engineering, quality assurance, and logistics departments. The aim of this collaboration was to prepare technical documentation for the newly produced component, which would subsequently be shared with the client. Commencing with an overview of Bosch's organizational structure, particularly focusing on the Bosch Mobility Solutions division and the Powertrain Solutions sector, this thesis introduces the Fuel Delivery Module, delineating its components, functionality, and Bosch's solutions portfolio, tailored to various vehicle characteristics. A comprehensive analysis of the relocation process, encompassing both general considerations and specific nuances related to the FDM, reveals decisions influenced by economic factors and the necessity to address external challenges such as the semiconductor crisis and escalating material costs, leading to the consolidation of production lines into a single plant. Activities associated with FDM relocation, notably the product validation tests conducted by the engineering team at Budweis, included "F and T Tests" aimed at evaluating the production capacity of the new plant, as well as durability tests designed to meet predefined criteria. Negotiations with the client determined the requisite documentation and prototypes to be furnished to each STLA plant, with delineated responsibilities for defining PPAP levels for individual FDM serial numbers, providing samples for high-volume serial numbers, and streamlining PSW documentation for others. The thesis concludes by highlighting significant challenges encountered, including communication with the client, the proposal of PPAP levels, and the coordination of workloads for the release of test reports, thereby serving as a valuable resource for comprehending Bosch's industrial relocation management and providing assistance to future interns or collaborators. Finally, reflecting on the future of mobility, the thesis acknowledges the growing trend towards electrification and Bosch's strategic investments in electric powertrain components, software development, and semiconductor technologies, positioning Bosch as a leading supplier within the automotive industry, poised for continued growth and innovation.