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I Congreso Innovación LEAN
Octubre 2018Dr. Jesús Fernández
La trayectoria de tk Norte en LEAN Manufacturing
2 |I Congreso de Innovación LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Elevator
Trayectoria LEAN en thyssenkrupp Norte
Una implantación en 2 oleadas2
Perfil de fábrica1
Experiencia en Japón3
4 Aprendizaje: fracasos y aciertos
Factory profile1
4 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
Factory profile: some key features for LEAN deployment
The Market The Product The Value Chain The Process The Company
Low volumes of 500~600 escalators per year
Long takt times: (2 shifts x 1.790 hours) / (500~600 units) = 6~7 hours
Product mix demand with high variability
Large & heavy:difficult to move ina flow
CustomizedMade to order
Global – long delivery times Raw material lead timelonger than customer demand
Low volume & customization: low power with suppliers
Labor intensive Within a corporationIncreasingly centralized
Stable workforce Unionized - resistant to change
Profitable
Low automation
Full testing required
Two waves for implementation
2
6 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
LEAN Journey: a long and winding road
- Time +
-L
EA
N P
erf
orm
an
ce
+
1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2018
1 MD x 13 years 3 MD x 7 years 1 MD x 7 years
No LEAN expert on board
OU
T
1st wave1998 - 2002
2nd wave2012 - today
tkPSA tail wind to
speed up
IN
The role of Management / Leadership / Know-how
7 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
LEAN Journey: 1st waveLEAN manufacturing (limited technical approach)
General AssemblyWelding
1996 1998 2000 2002 2004 2006
LEAN training1 expert developed
Lighthouse project:Steps coating line
MUDA AnalysisHEIJUNKAKANBAN
Welding-shop:Moves + new lay-out
Flow line 1:8 hours takt
New lay-outU-shape cellsMini-factories
New jigs + Robot
4 hours takt in Flow line
- No sound LEAN knowledge available
- Flow line without constant takt
- High volume output
- Product portfolio changes in 2003
- Priorities (for white collar) adressed to other hot topics (Toronto, China, …)
8 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
MUDA Analysis
Logistics merge Warehouses & Procur.FaMa KPI
LEAN Journey: 2nd waveHolistic approach + LEAN Management
2010 2012 2014 2016
Lighthouse Project: Press Brake cell
5S
Inverted PyramidOrganization
Welding-shop synchronized
SQDC
MIZUSUMASHI
5x2 + 3 plan to ensure FLOW
BPDA3SGT
MUDA AnalysisNew SWS in Flow line
KAIZENOrganization
Tugger trainMilk run Flow line 2
New LEAN expert
tkPS
tkPSAudit 1
tkPSAudit 2
tkPSAudit 3
General AssemblyWelding
CorporateLogistics
Japaneseexperience
3
10 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
Japanese experience: the source of LEAN knowledge
CHALLENGE
KAIZEN
GENCHI GENBUTSU
CONTINUOUS
IMPROVEMENT
RESPECT
FOR PEOPLE
RESPECT
TEAMWORK
Toyota WayThe human(istic) touch
RESPECT
Cleanness level
SHOES OFF!
Continuous improvement HUNGER
KAIZEN teams
TEAMWORK
Suppliers integration with KANBAN
KANBAN = $
e-KANBAN
Learnings:failures & success
4
12 I Congreso Innovacion LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Norte
Failures = Learnings
The human(istic) touch
RESPECT
Cleanness level
SHOES OFF!
Continuous improvement HUNGER
KAIZEN teams
Suppliers integration with KANBANKANBAN = $e-KANBAN
customer claims + CoPQ
due to lack of standardization &
poor Q mindset
5S poor implementation
Too many audits (6S tk standard)
fights with workforce
LEAN deployment despite people wishes
suppliers not developed/integrated
FaMa
(not very) LEAN Logistics
13 |I Congreso de Innovación LEAN | Trayectoria LEAN de tk Nortethyssenkrupp Elevator
Some successful stories to highlight
TEAMWORK ORG SQDC + BPD SGT (MES) & tabletsInverted pyramid organization Boards for shop floor management &
teams involvementKey data collection to drive KAIZEN
First steps to 4.0 factory
FLEXIBLE TAKT LINES PARTS MANUFACT. CELLS LOGISTICS
1 piece flowWelding + Assembly80÷90% product mix
Steel plate parts
SMED in bending
Mizusumashi&
Milk-run
