MOLEX AUTOMOTIVE SARL

VILLEMUR PLANT

Division Transportation

CONNECTORS LOCATION
Interconnection
module

ECU applications

Passenger-cabin
application

Sealed connector

Sealed Through Panel

connector
Firewall connector

Division Global Transportation

Division Global Transportation

Villemur s. Tarn France

01-04-2004

Kosice Slovakia

HQ Ettlingen Germany

Molex SARL Villemur Staff

Philippe FORT
General manager
manager

Rapha
Raphal REMAUD
Prod. Quality

Coline COLBOC
Human Resources

David FRAN
FRANOIS
Abdoul LY

Logistics

Accounting

St
Stphane MICHEL
Engineering

Christiane CARQUILLE

GM assistant

Ali OUDRHIRI

Marc GAILLARD

Laboratory

CCI Molding

JeanJean-Jacques
PELISSIER

Toolroom

Thierry ROQUES
Eric POURCHET
Customer Quality

Sylvain AURIOU
Sylvain AURIOU
CCI Stamping

CCI Assembly

Process engineering department

34 skilled technicians and engineers
2 mains activities :
Project management
New product Processes
Mature products (design and process improvement)

Process expertise
Molding
Stamping
Assembly

Facilities :

CAD : CATIA V5, MISSLER and AUTOCAD

Rheology : mold flow
Crimping laboratory and prototypes work cell
Villemur manufacturing facilities

Laboratory
Testing :
Internal facilities to fulfill all the customers
requirements

Calibration :
The Lab manages the calibration of all the
plants measuring devices (2300 units)

Environmental activities :
IMDS and specific Customer
Environmental Requests

Stamping
13 high speed presses (400 1 000
strokes /min) from 20 to 60 Tons
150 mass production tools;
49 employees, 3 shifts ;
Bi component terminals ; laser
welding;
10 Continuous and automatic video
control systems and Quality control
cells

Stamping organization
Cells organization:
Cell 1
Family CP and MOX terminals

3 cells in the workshop according to terminal families

2 operators per cell

Cell 2
Family New-SCC/H3/HDX

Production in 3 shifts, 7 days a week

3 cells in the dies maintenance by product family

Cell 3
Family VDL/ CSP/Ring tons

Molding activities
38 horizontal injection presses
from 60 to 200 Tons with a
complete process control
Raw material distributed by
automatic centralized feeders and
dryers.
Around 150 mass production
molds;
Pressure sensor control; hot
runners
54 employees (production,
maintenance and support) 5
shifts, 7 days a week

Assembly
18 fully automatic assembly
machines
5 shifts, 7 days a week (part time
night and week-end)
37 employees
3 production lines including
Molding and Assembly

Molding / Assembly

Organization
production molding assembly on-line

Line Production
organization

Visual flow of
material

Quick handling
components

Any stock in
warehouses

Molding / assembly
Product/ Process line management

Key point :

Team manager /
Planner / Maintenance
Development of people
versatility
Quick Reactivity on
Quality issues
Customer to supplier
relationship
Integrated Quality
management within
each line

Logistic
1000 m storage area
25000 boxes maximum capacity
2 shifts model
7900 lines delivered monthly
251 delivery points
Key points :
Customer logistic team
CRD 96,8%
MPD 97,8%
Lead Time 6,7 days

Logistic
On board SAP terminal & printer
4 foreclifts
Bulk solution
Transportation SAP module
RF SAP

General Toolroom
Activities :
new tools,
spare parts

31 employees

Standard machining : milling,

turning, surface grinding
machines
2 profile grinding machines

General Toolroom
EDM

3 wire EDM machines

3D measuring machine

4 plunging EDM machines

1 high speed machining center for
graphite electrodes

Quality In Production
Molding :
INJECTION QUALITY TABLE :
Injection parameters followed non-stop, all parts produced with a parameter out
of tolerance is segregated by a quality flap
FUNCTIONAL TESTING :
Products controlled through functional tests simulating the customer usage
Assembling :
QRQC
Daily analyze of the Assembling red boxes to
detect any deviation on the process and
correct it in a short time

Stamping :
3D MEASUREMENT :
Dimensional analyze of the terminals done with
Mitutoyo 3D vision
machine.
SAP LINK :
Direct upload of measurement results to SAP
system.

SAP in Molex Automotive

Molex choose to have ONE SAP computer database worldwide
This computer / database is located in Chicago
Molex Automotive has implemented all of the standard modules
These include:MM Material Management
PP Production Planning
SD Sales & Distribution
FI Finance
CO Controlling
QM Quality Management
HR Human Resources (Q4)
Adding new functionalities for Automotive:Handling Unit Management (HUM)
Using Radio Frequency Devices in Production area and
warehouse
Advanced EDI capabilities
Transportation module elements

Thank you
Division Global Automotive