WEBVTT 00:00:10.960 --> 00:00:12.700 Scania is a leading company 00:00:12.700 --> 00:00:16.880 and is regarded as a premium brand whose profitability has always been good. 00:00:17.540 --> 00:00:20.400 To maintain our reputation and our competitiveness, 00:00:20.400 --> 00:00:21.800 we must continue to improve 00:00:21.940 --> 00:00:26.220 and meet our customer’s rising expectations with regard to good quality. 00:00:27.080 --> 00:00:30.540 Cleanliness is one of the key elements in achieving this quality. 00:00:33.840 --> 00:00:38.240 Scania is driving the shift towards a more sustainable transport system. 00:00:38.520 --> 00:00:41.020 We are doing that by providing powertrains 00:00:41.020 --> 00:00:44.620 that can run on all available alternative fuels 00:00:44.840 --> 00:00:49.780 and by providing powertrains that are the most fuel efficient in the world. 00:00:51.420 --> 00:00:54.000 The powertrains that we will be providing 00:00:54.080 --> 00:00:57.980 demands a precision in our production processes 00:00:57.980 --> 00:01:00.720 that we have never seen before. 00:01:01.260 --> 00:01:03.260 And that’s where cleanliness come in. 00:01:03.270 --> 00:01:04.980 That’s where you come in. 00:01:05.760 --> 00:01:09.560 We need to be more and more precise in our processes, 00:01:09.860 --> 00:01:12.360 we need to be better and better in how we 00:01:12.380 --> 00:01:14.740 take care of the product that we produce. 00:01:16.600 --> 00:01:20.080 In this film you will learn how important cleanliness 00:01:20.080 --> 00:01:23.700 is for our production processes and for our products. 00:01:23.960 --> 00:01:26.760 And you will learn how important you are 00:01:26.760 --> 00:01:30.100 to make sure that we get to that standard that we need. 00:01:30.840 --> 00:01:33.060 You will learn how important it is to 00:01:33.400 --> 00:01:35.720 learn your standards, know your standards, 00:01:35.720 --> 00:01:37.840 apply them each and every day 00:01:37.940 --> 00:01:40.160 and improve them each and every day. 00:01:46.800 --> 00:01:49.320 One of Scania's trucks has got a problem. 00:01:49.860 --> 00:01:51.220 What will the driver think, 00:01:51.300 --> 00:01:53.440 what will the haulier or a passer-by think, 00:01:53.440 --> 00:01:55.860 when they see a Scania truck at the roadside? 00:01:56.460 --> 00:02:00.600 A drop of oil, a fingerprint or a small particle in the wrong place 00:02:00.600 --> 00:02:03.800 could cause serious problems for a truck, bus or engine. 00:02:04.640 --> 00:02:06.980 Downtime for one of Scania's customers 00:02:07.140 --> 00:02:10.920 can be expensive both for Scania internally and for the customer. 00:02:11.800 --> 00:02:15.340 Any problem with a vehicle, a truck or bus at the roadside 00:02:15.420 --> 00:02:18.700 can also cause serious damage to the proud reputation of Scania. 00:02:20.140 --> 00:02:23.020 Scania products have many components and media systems 00:02:23.020 --> 00:02:25.020 which are sensitive to contamination. 00:02:26.100 --> 00:02:29.280 When components are manufactured, particles are generated. 00:02:29.680 --> 00:02:31.200 If these, for example, 00:02:31.200 --> 00:02:34.360 find their way to the sensitive lead-free bearings in the engine, 00:02:34.540 --> 00:02:37.840 this can result in bearing damage and engine breakdown. 00:02:38.700 --> 00:02:43.660 Particles in an oil system (for example in a gearbox, axle or engine) 00:02:43.960 --> 00:02:49.100 also cause wear to gears, bearings, sliding surfaces and so on. 00:02:49.740 --> 00:02:53.060 Particles can be pressed into the surface and cause damage. 00:02:53.540 --> 00:02:57.140 This can result in greater friction and increased fuel consumption, 00:02:57.300 --> 00:03:00.060 thus shortening the service life of the product. 00:03:00.500 --> 00:03:04.400 A small particle in the fuel injector can cause a reduction in performance, 00:03:04.520 --> 00:03:08.560 increase exhaust emissions or lead to total breakdown of the engine. 00:03:09.100 --> 00:03:10.680 It may clog the spray holes 00:03:10.800 --> 00:03:13.860 through which fuel is injected into the combustion chamber 00:03:13.960 --> 00:03:17.400 or prevent the valve controlling fuel injection from closing. 00:03:17.860 --> 00:03:20.440 In joining operations, such as gluing, 00:03:20.540 --> 00:03:23.440 it is extremely important for the surfaces to be clean. 00:03:24.140 --> 00:03:27.040 For example, the gear changing function in a gearbox 00:03:27.040 --> 00:03:29.980 may fail completely if the surface is dirty and 00:03:30.060 --> 00:03:34.320 the carbon fibre coating on the synchromesh is not attached properly. 00:03:35.740 --> 00:03:39.700 Surface cleanliness is also extremely important when painting 00:03:39.780 --> 00:03:41.980 and applying other surface treatments. 00:03:42.820 --> 00:03:46.540 Contamination, particles or fibres as well as silicones, 00:03:46.540 --> 00:03:50.120 grease or fingerprints can result in visual defects 00:03:50.280 --> 00:03:54.620 but may also risk causing paint delamination, blistering and corrosion. 00:03:55.920 --> 00:04:00.000 We also have major risks associated with poor cleanliness and leakage. 00:04:01.080 --> 00:04:03.700 For example, a hair on a sealing surface 00:04:03.820 --> 00:04:07.160 may prevent two parts from sealing, resulting in leakage. 00:04:08.240 --> 00:04:11.060 This can in turn lead to both a loss of function 00:04:11.080 --> 00:04:14.840 and leakage of media such as engine oil, air or coolant. 00:04:15.380 --> 00:04:18.960 With the increasing focus on e-mobility and sustainable transport, 00:04:19.280 --> 00:04:22.440 there will also be new challenges associated with cleanliness, 00:04:22.660 --> 00:04:26.100 such as in the manufacture of electric machines and batteries. 00:04:26.660 --> 00:04:28.720 These are just some of the examples 00:04:28.720 --> 00:04:31.340 where the right level of cleanliness is important 00:04:31.360 --> 00:04:33.480 to ensure the quality of our products! 00:04:34.700 --> 00:04:37.840 It’s not just Scania’s customers that will be affected. 00:04:38.400 --> 00:04:41.640 Internally, a quality deviation due to poor cleanliness 00:04:41.780 --> 00:04:44.560 will result in extra work and additional costs. 00:04:45.840 --> 00:04:49.740 Deviations may result in production and delivery stoppages 00:04:49.740 --> 00:04:53.980 and extra manual work, such as rework or extra cleaning. 00:04:55.160 --> 00:04:59.140 This in turn causes disruptions to all of us working on the product 00:04:59.240 --> 00:05:02.820 and takes time and energy from the value adding work. 00:05:09.940 --> 00:05:12.780 This is what we call the cleanliness chain. 00:05:13.040 --> 00:05:15.440 It describes the entire flow of a product 00:05:15.520 --> 00:05:17.900 from the design stage to the customer, 00:05:18.020 --> 00:05:19.840 from a cleanliness perspective. 00:05:21.160 --> 00:05:25.240 The cleanliness chain describes the most fundamental aspects of cleanliness: 00:05:25.520 --> 00:05:28.060 the fact that the cleanliness at each step 00:05:28.160 --> 00:05:32.660 is equally important to achieve the quality we need in the final product. 00:05:33.600 --> 00:05:38.660 That’s why it is so important to take on responsibility at every step in the chain 00:05:38.940 --> 00:05:40.740 – for you to do what you can. 00:05:41.900 --> 00:05:46.480 The work on cleanliness begins when designing different products and media systems, 00:05:46.740 --> 00:05:48.900 such as the oil or fuel system. 00:05:49.820 --> 00:05:54.240 Design engineers work together to set cleanliness requirements for the parts, 00:05:54.640 --> 00:05:57.420 based on the level of cleanliness the system requires 00:05:58.000 --> 00:06:00.400 but also to create the conditions for production 00:06:00.440 --> 00:06:02.840 and logistics to meet these requirements. 00:06:03.860 --> 00:06:06.580 The purchasing department is the department 00:06:06.580 --> 00:06:09.020 which ensures that our external parts 00:06:09.060 --> 00:06:11.620 are purchased in accordance with these requirements. 00:06:12.280 --> 00:06:15.500 Only if we get the right quality delivered to Scania 00:06:15.720 --> 00:06:18.600 can we guarantee the right quality to our customer. 00:06:19.360 --> 00:06:21.920 Machining, logistics and assembly 00:06:22.020 --> 00:06:24.500 are obviously extremely important elements, 00:06:24.920 --> 00:06:28.560 and something we will take a closer look at in the following sections. 00:06:29.120 --> 00:06:33.040 But the cleanliness chain goes all the way to the service market, 00:06:33.160 --> 00:06:36.500 which looks after our products as they are used by the customer. 00:06:37.240 --> 00:06:38.800 When servicing a vehicle, 00:06:38.800 --> 00:06:42.360 it is necessary to fix any deviations without adding particles 00:06:42.800 --> 00:06:45.780 – particles that could rapidly lead to new problems. 00:06:46.240 --> 00:06:49.180 The chain is only as strong as its weakest link. 00:06:50.020 --> 00:06:52.620 Right from me in all parts of the chain 00:06:52.680 --> 00:06:56.320 is of the utmost importance for us to succeed together. 00:07:02.080 --> 00:07:03.860 But what is a deviation? 00:07:04.240 --> 00:07:06.840 When is a component “too contaminated”? 00:07:07.020 --> 00:07:08.520 When do we need to react? 00:07:09.500 --> 00:07:13.380 This depends on the requirements of each component and media system. 00:07:14.380 --> 00:07:17.000 Different contaminants have different impacts 00:07:17.040 --> 00:07:19.080 on different surfaces and systems. 00:07:19.680 --> 00:07:21.720 One of the challenges of cleanliness 00:07:21.720 --> 00:07:25.040 is that a deviation can be caused by anything from fingerprints 00:07:25.080 --> 00:07:27.360 and hair strands to metal particles. 00:07:28.520 --> 00:07:32.220 When it comes to particles we cannot always see in production 00:07:32.240 --> 00:07:34.680 if a component complies with the requirements. 00:07:35.240 --> 00:07:40.680 We can only be certain that a component is okay by analysing it in a cleanliness lab. 00:07:41.460 --> 00:07:44.960 When a cleanliness analysis is carried out on the components, 00:07:45.180 --> 00:07:48.460 all particles are collected and counted under a microscope. 00:07:48.860 --> 00:07:52.760 In some cases, the particles we want to avoid are so small 00:07:52.760 --> 00:07:56.360 that it’s impossible for a person to detect them with the naked eye. 00:07:57.040 --> 00:08:00.560 The particles we want to avoid are measured in micrometres, 00:08:00.680 --> 00:08:03.900 in other words one thousandth of a millimetre. 00:08:04.340 --> 00:08:08.660 The smallest particles we are looking for are much smaller than a hair’s breadth. 00:08:09.220 --> 00:08:13.240 Very small particles can be harmful to some systems and surfaces. 00:08:14.060 --> 00:08:17.140 Larger particles can also be very difficult to detect, 00:08:17.320 --> 00:08:20.460 such as a metallic particle on a metal component. 00:08:22.140 --> 00:08:24.240 One of these particles, in the wrong place, 00:08:24.340 --> 00:08:26.240 could cause serious problems. 00:08:27.160 --> 00:08:31.800 Not all components and media systems are equally sensitive to contamination. 00:08:32.260 --> 00:08:35.680 It’s important to know which components and surfaces are sensitive, 00:08:35.900 --> 00:08:39.500 so that we can focus our work on cleanliness in the right places. 00:08:40.340 --> 00:08:42.860 Since we cannot always see the deviations, 00:08:43.100 --> 00:08:47.580 it is all the more important for us to follow our standards and procedures. 00:08:52.520 --> 00:08:55.220 But where do all these particles come from? 00:08:55.600 --> 00:08:59.300 How can we avoid quality deviations due to poor cleanliness? 00:09:00.080 --> 00:09:03.780 Where we have sensitive components or assemble sensitive media systems, 00:09:03.940 --> 00:09:06.740 it is important for us to have good work procedures, 00:09:06.740 --> 00:09:08.140 and for us to follow them. 00:09:08.540 --> 00:09:10.300 The cleaning processes we have, 00:09:10.380 --> 00:09:12.460 especially in our machining areas, 00:09:12.640 --> 00:09:16.600 are among the most important steps for the cleanliness of our parts. 00:09:17.060 --> 00:09:21.480 It is important for there to be clear machine ownership of each washing machine 00:09:21.550 --> 00:09:23.940 and for continuous maintenance to be carried out, 00:09:23.940 --> 00:09:27.260 to keep the washing machines in the best possible condition. 00:09:27.820 --> 00:09:30.200 Once the components are washed and clean, 00:09:30.200 --> 00:09:32.980 the aim is to make sure that they stay that way. 00:09:33.380 --> 00:09:35.700 When handling clean, sensitive parts, 00:09:35.800 --> 00:09:39.400 for example for quality checks, order picking or assembly, 00:09:39.660 --> 00:09:44.120 the use of clean gloves is one way to reduce the risk of contamination. 00:09:45.040 --> 00:09:46.920 It is also important for us to know 00:09:46.940 --> 00:09:50.400 which surfaces are sensitive and handle the parts correctly. 00:09:51.120 --> 00:09:55.700 Sensitive components need to be protected from the environment, which may be dirty. 00:09:56.080 --> 00:10:00.260 This applies, for example, to logistic flows and in assembly 00:10:00.320 --> 00:10:03.060 until the sensitive surfaces are protected. 00:10:04.220 --> 00:10:07.420 Well-designed packaging which is handled correctly 00:10:07.420 --> 00:10:10.260 ensures the quality of the parts during transport 00:10:10.320 --> 00:10:12.360 and until the package is opened. 00:10:12.760 --> 00:10:15.320 A package should be undamaged and clean. 00:10:16.140 --> 00:10:19.360 Once the material has been delivered to the assembly line, 00:10:19.360 --> 00:10:22.680 the packaging and protective plugs should be kept closed, 00:10:22.680 --> 00:10:25.000 until it is time to assemble the part, 00:10:25.400 --> 00:10:27.660 to minimise the risk of contamination. 00:10:28.220 --> 00:10:31.060 Particles can also be created during assembly, 00:10:31.260 --> 00:10:33.400 such as when cracking connecting rods, 00:10:33.400 --> 00:10:36.360 when pressing components or when tightening a bolt. 00:10:37.380 --> 00:10:41.180 Particles can also be generated during disassembly or rework. 00:10:42.120 --> 00:10:45.760 It is therefore important to consider where the particles end up 00:10:45.840 --> 00:10:48.680 and comply with the procedures to minimise risks. 00:10:49.780 --> 00:10:54.640 All tools that come into contact with a component can affect its cleanliness. 00:10:54.980 --> 00:11:00.140 For example, a lifting tool can chafe off material and generate particles. 00:11:00.580 --> 00:11:03.440 The tools must be designed and used correctly 00:11:03.660 --> 00:11:05.980 and cleaned according to the standard. 00:11:06.460 --> 00:11:08.960 Grease used during assembly is sticky 00:11:09.040 --> 00:11:11.060 and can easily attract particles. 00:11:11.340 --> 00:11:13.580 We must look after our grease containers 00:11:13.580 --> 00:11:16.180 and use good methods to supply the grease 00:11:16.240 --> 00:11:18.940 to avoid particles and paint brush bristles 00:11:19.080 --> 00:11:20.760 ending up in the wrong place. 00:11:21.000 --> 00:11:23.980 It’s important not to take dirt into areas 00:11:24.040 --> 00:11:26.000 where there are sensitive components. 00:11:26.240 --> 00:11:29.140 We must consider where our shoes and clothes have been. 00:11:30.060 --> 00:11:32.100 The work area should be kept clean 00:11:32.120 --> 00:11:34.760 by following the available cleaning procedures. 00:11:35.180 --> 00:11:38.220 Cleaning can spread particles instead of removing them. 00:11:38.540 --> 00:11:40.980 Sweeping a surface or blowing something off 00:11:41.060 --> 00:11:44.900 with compressed air can cause particles to swirl around in the air 00:11:44.940 --> 00:11:47.080 and contaminate a sensitive part. 00:11:47.340 --> 00:11:50.700 Vacuuming or wiping with a clean lint-free cloth 00:11:50.820 --> 00:11:52.960 are examples of good cleaning methods. 00:11:53.860 --> 00:11:55.760 When maintaining tools and machines, 00:11:55.820 --> 00:11:59.620 it is important to remember that cleanliness is a quality parameter. 00:12:00.300 --> 00:12:02.860 We must look into the risks and manage them. 00:12:04.440 --> 00:12:07.000 Through right from me in all situations, 00:12:07.180 --> 00:12:10.900 we reduce the risk of contaminating our products with particles. 00:12:11.420 --> 00:12:13.380 And we also put the customer first. 00:12:18.760 --> 00:12:20.860 When handling sensitive components, 00:12:20.860 --> 00:12:25.320 a risk assessment should be carried out that focuses on cleanliness. 00:12:25.920 --> 00:12:28.000 The risk assessment may indicate 00:12:28.000 --> 00:12:30.940 that some areas require additional protection, 00:12:31.080 --> 00:12:33.620 that a "clean zone" is required. 00:12:34.360 --> 00:12:36.980 There are different levels of cleanliness zones 00:12:36.980 --> 00:12:38.800 where parts with higher cleanliness 00:12:38.820 --> 00:12:41.120 requirements are handled or assembled. 00:12:42.100 --> 00:12:47.000 The cleanliness zones can be found in machining, assembly and logistics. 00:12:47.500 --> 00:12:49.680 The cleanliness zones are clearly marked 00:12:49.800 --> 00:12:52.400 by means of green floor markings and signs. 00:12:53.320 --> 00:12:57.360 Inside these markings special standards and procedures apply 00:12:57.500 --> 00:13:01.760 in order to ensure the quality of the components handled at these stations. 00:13:01.780 --> 00:13:04.900 It is therefore important for you to talk to the team leader 00:13:04.940 --> 00:13:07.240 before you enter a cleanliness zone. 00:13:07.720 --> 00:13:11.400 Standards and procedures can cover how to keep the area clean, 00:13:11.600 --> 00:13:14.200 how a package should be opened or how a part 00:13:14.220 --> 00:13:17.000 should be handled and protected in the area concerned. 00:13:17.860 --> 00:13:21.320 We can use cleanliness risk assessments and clean zones 00:13:21.320 --> 00:13:25.320 to ensure that our sensitive components are protected against contamination 00:13:25.460 --> 00:13:28.460 and that our products fulfil our quality requirements. 00:13:33.600 --> 00:13:36.260 The correct level of cleanliness in our products 00:13:36.320 --> 00:13:38.740 will help to keep our vehicles on the road, 00:13:38.900 --> 00:13:41.460 with a better and better level of performance. 00:13:42.400 --> 00:13:45.320 It’s when we work together to improve our products 00:13:45.520 --> 00:13:48.660 that we drive the shift towards sustainable transport 00:13:48.780 --> 00:13:51.660 and help to maintain our status as a premium brand. 00:13:53.000 --> 00:13:56.460 In this film you have learned how important cleanliness is 00:13:56.640 --> 00:13:59.820 for us and for our products and for our customers. 00:14:00.220 --> 00:14:03.560 You have seen how important it is to know your standards, 00:14:03.640 --> 00:14:07.460 to follow your standards, and to improve your standards day by day, 00:14:07.700 --> 00:14:09.760 you together with your team. 00:14:10.660 --> 00:14:16.200 I would love if you could reflect after having seen this film on what you can do, 00:14:16.360 --> 00:14:19.680 to contribute to Scania driving the shift.