Thursday, April 30, 2020

ZF Friedrichshafen - Industrial Engineering Activities and Jobs

Industrial Engineering - Productivity Improvement - Process Improvement - Product Redesign - Continuous Improvement

Industrial engineering is improvement in various elements of engineering operations to increase productivity. Along with engineering elements, industrial engineers evaluate and improve many other elements also as they are responsible for productivity and cost of items produced in a process. Through assignments of improving productivity and efficiency of information technology and software engineering processes, industrial engineers specializing in IT were given responsibility for business processes also. Thus industrial engineers with focus on various branches of engineering provide their services to companies and society to improve various elements of the products and processes on a continuous basis over the product life cycle. They are active in engineering or production-maintenance-service-logistic processes and business processes.

Productivity improvement always focuses on quality and flexibility issues as productivity improvement should not lead to any deterioration in quality or flexibility. Delivery and cost are always at the core of industrial engineering. Thus when QFCD paradigm came, that is attention to quality, flexibility, cost and delivery became prominent, many industrial engineers were given the responsibility of managing this function of continuous improvement.



Focus Areas of Industrial Engineering - Brief Explanation

Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity

Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering

Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering

Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers

Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering

Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers

Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering

Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements

Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management

Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.
Applied Industrial Engineering - Process Steps

How many Industrial Engineers can a Company Employ for Cost Reduction?
For $100 million cost, there can be one MS IE and 6 BSIEs.

Industrial Engineering - Lean Manufacturing - Parent - Child Relationship

ZF Friedrichshafen

Zf Friedrichshafen Ag
Principal Product Value Engineer
Livonia, Germany

Job description
Req ID 20573BR

Job Title: Principal Product Value Engineer

Business Unit Automotive Staff - Purchasing
Job Description Primary Responsibilities:

Identify, develop, and implement Value Analysis/Value Engineering (VA/VE) projects for the braking product line within ZF TRW Active and Passive Safety Technology.
Generate and develop cost reduction and product value improvement engineering projects.
Coordinate internal and external resources (internal cross functional team, customers and supplier) for the flawless execution of projects to cost target, on-time delivery, to meet design integrity.
Manage project approvals within company procedures and ensure proper planning.
Assist in the definition of project scope and objectives, involving all relevant stakeholders and ensuring technical feasibility.
Develop detailed project plans to monitor and track progress.
Use company systems to manage changes to the project scope, project schedule, and project costs using appropriate verification techniques & update management accordingly.
Measure project performance using appropriate tools and techniques.
Perform business case and risk management to assess project risks.
Lead workshops internally and externally to generate competitive benchmarking and cost reduction ideas.
Strong contribution to the development and fulfillment of the product line’s annual operating plan savings target is important.

Minimum Requirements:
Bachelor’s degree in Engineering is required, Mechanical Engineering preferred.
Minimum of 5 years in automotive or similar industry analyzing and reducing costs.
Experience with castings is highly preferred.
A balanced and solid background of engineering, manufacturing and business.
Proven working experience in project management in the manufacturing sector.
PMP certification is a plus.
Travel 10% to support workshops and supplier visits.
Education Requirements Bachelors Degree in Engineering required
Experience and Skill Requirements 5+ years of related experience

Athmiya Venkatesh
Purchasing Professional Specializing in Cost Reduction and Data Analysis.
Clinton Township, Michigan
Cost Analysis • Data Structure Analysis • Cost Management • Process Analysis
ZF Friedrichshafen
Since Dec 2015 Washington, Michigan
I accurately track and report financial impact of cost modeling projects and act as a Business Unit consultant to consistently drive down bill of material cost by working with Global Purchasing commodity and Engineering. I create synergy between sourcing decisions and engineering decisions by embedding Cost Modeling in the BU.

ZF Friedrichshafen AG joins the Open Manufacturing Platform (OMP) to enable faster and more cost efficient innovations in the manufacturing sector. 

Aimed at accelerating and scaling the development of manufacturing applications, ZF Friedrichshafen joined Open Manufacturing platform announced by BMW and Microsoft in 2019
ZF Friedrichshafen AG has announced to join the Open Manufacturing Platform (OMP) that aims to enable faster as well as more cost efficient innovations in the manufacturing sector.

ZF at the BAUMA China 2019
 concepts determine the trends in the construction industry.

ZF as a “global player” for Driveline technology  offers the so called “Best Choice Strategy” for Optimized fuel consumption, higher efficiency, cost reduction and innovative design. Our customers are able to select between different modular transmission and axle concepts. The technology levels Basic-, High- and Premium line are tailored to the needs of the different customers and applications. The perfect solution for future challenges in global markets.

ZF Premium line products – developed for superior performance. With the EFFICIENCY PACKAGE ZF is defining new standards by reducing fuel consumption up to 25 % and increasing productivity up to 20 %.

Inspection Industrial Engineering

3D Quality Inspection Of Gear Transmission Casings For Commercial Vehicles
ZF Friedrichshafen - Germany

ZF's Model Factory Features Smart Interfaces Between Delivery and Production Logistics



Our aim is to concentrate on few suppliers to ensure the most profitable conditions considering TCO (Total Cost of Ownership).

Costs for production material account for more than 60 percent of our turnover which make them the
largest pool of costs and showcase the importance of materials management for the success of ZF.
Therefore, ZF will continue to focus on its need for efficient and innovative suppliers.

Through excellence in quality, logistics, and cost-cutting, suppliers recommend themselves for new orders within new projects.

The suppliers with the best possible cost situation and total performance will get the assignment.

Cost Engineering at ZF is in charge of monitoring the ideal cost structures. To achieve optimal cost
structures on the parts level, our basic procurement method is single sourcing.

 To ensure a systematic approach to the use of energy and resources, we will discuss our objec tives with you and determine the appropriate measures to meet them.

The supplier is an integral part of our development team. Early supplier involvement will help shorten development times and reduce costs. A further goal is the development of system suppliers.

It is our objective to involve the supplier in the product creation process at an early stage in order to sustainably influence the procurement costs and to increase the company’s innovativeness.

Pursuing the approach of Simultaneous Engineering, we avoid work redundancies and preserve valuable capacities. The supplier is expected to bring to the table his know-how and to take charge of detailed design and engineering work. This will help shorten development times and significantly reduce the costs for development, modeling, tools, and materials.

About 80 percent of the costs are determined by product design. Together we must establish optimum cost structures to achieve the target prices determined by the global market.

Strategic Cost Management

Cost transparency is necessary to identify cost-driving factors and to optimize cost structures.

We make our decisions based on competitiveness and always consider the total costs within the supply chain. For existing products, ZF will work with the suppliers in interdisciplinary value analysis teams. We want to change from annual price negotiations to on-going, open cost discussions. In doing so, the objective is not to challenge the suppliers’ profits, but to identify and eliminate the cost-driving factors caused by both sides in the product and process design and therefore jointly
achieve the best cost level.

To choose the right suppliers for Early Supplier Involvement, it is important to understand these suppliers’ cost structures and, as far as possible, have an overview of the entire supply chain. Sufficient cost transparency is a prerequisite for determining which suppliers are be able to achieve the target costs. This requires a team environment with the readiness and ability to openly discuss existing and possible cost structures while also creating new ones. We are ready to further bundle our requirements and make long-term commitments, when possible, to one supplier for each parts family.
The goal is to also maximize the profitability of our suppliers in relation to the global market cost level.

Supplier Management

Supplier development for the systematic optimization of technology, quality, costs, and logistics.

ZF Friedrichshafen AG
Corporate Materials Management
D-88038 Friedrichshafen
Phone +49 7541 77-0
Fax +49 7541 77-908000

ZF Industry 4.0

ZF Friedrichshafen as part of its Sustainable Reduction Plan made a goal to reduce energy consumption at its global facilities 20% by 2015 compared with 2010.

The German supplier last year decided energy consumption not only was a sound business strategy to reduce cost, but also a social responsibility according to  Kelly Biers, director-continuous improvement, ZF North America.

Module 1 Assistance in Production


Module 4- Hard Machining


Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.

Index to Industrial Engineering Practice in Top Global Manufacturing Companies - Top 100

Online Handbook of Industrial Engineering


  1. Congratulations on completing the A-Z! And thanks for visiting my blog. =)
    Black and White (Words and Pictures)

    1. Thank you. Your comment made me set my direction today towards visiting other blogs. Visited around 50 today. Shall do more in the coming days. Thank you.

  2. Congratulations on completing the challenge! Your theme is a little too technical for me, sorry, I didn't visit a lot...
    Stay safe and take care.
    Z is for Zakka

    1. Thank you. That is fine. We have limited time and we have to use it for best purposes. Even I am selective.

  3. Congratulations on completing the challenge. This is some precious information for those in the field. I couldn't visit your blog much as it's not my core area of focus. Apologies.

    1. Welcome. Yes we know that interests of A to Z bloggers are diverse. Limited connect is sufficient to motivate each other.

  4. Congratulations on completing A-Z April 2020 Challenge, thank you for visiting my blog and appreciate your comment.