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1
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
IPA Slovakia – Brief Profile
Združenie
Fraunhoferovej spoločnostia Žilinskej univerzity
Združenie
Fraunhoferovej spoločnosti
2
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Frau
nhof
er
Leading Organisation for appliedResearch in Europe58 Institutes in Germany12000 EmployeesPresident: Prof. Dr.-Ing. J. Bullinger
Fraunhofer Germany
Fraunhofer USA
Fraunhofer Asia
3
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Fraunhofer IPA –Institute of Production
Technology and Automation, Stuttgart
4
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Fraunhofer IPA
Prof. Dr.-Ing. Rolf Dieter SchraftProf. Dr.-Ing. Engelbert Westkämper
5
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
IPA SlovakiaJ.Košturiak – Managing Director, R.Debnár – Vice Managing Director
Corporate Organisation – Innovations, Productivity improvementprogrammes, Organisation structures, Process management, LeanSigma
R.DebnárManufacturing systems and
logistics
-Layout
- Manufacturing cells
- Manufacturing teams, visualisation
- Simulation/ inventories
- Material flow / informationflow
- Kanban
M.KyseľProcess optimisation
- Continuous processimprovement
- Value stream mapping
- Production lineimprovement
- Setup time reduction –SMED
- Quality assurance
J.KrišťákWorkplace and workforce
productivity
- Work analysis and measurement
-TPM
- Job analysis
- Workplace organisationand ergonomy
- Theory of Constraints, bottlenecks
Ľ.BoledovičTraning, education
- Master study
- Trainings
- Coaching
- Lean Six Sigma trainings
- Management trainings
- Supervisor trainings
- Lean Academy
Centralizované fraktály
Fi nancie, controlingTechnické centrumPredaj, Marketi ngRiadenie kvali ty
Informačné technológieLogi stika, Nákup
Správa majetku a údržbaRiadenie ľudských zdrojov
Výrobný frakt álVHP
Výrobný fraktálSHP
Údržba Prac.tímy
Prac.tímy
Údržba
Generálny ri aditeľ
Čl en predst avenstva Čl en predst avenstvaPredseda predstavenstva
Výrobný fraktálBanja Luka
Výrobný fraktálSlavošovce
Kval i t aPl ánovani e výroby
Tech. zabezpečeni eNákup j ed. mat er i ál u
M aj st r i
Kval i t aPl ánovani e výrobyTech. zabezpečeni e
Nákup j ed. m at er i ál uM aj st r i
6
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Network – Germany, Austria, Slovakia, Czech Republic
7
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Alcatel Slovakia, a. s. · AMROP JENEWEIN GROUP, Bratislava · Autokabel Slowakia, spol. s r. o. · AUTOKAROS, a. s. ·Barum Continental, spol. s r. o. · Bauer Consulting · BIC GROUP, spol. s r. o. · BMW AG · Boge Slovakia a. s. ·
BONATRANS, a. s. · Brose Bratislava, spol. s r. o. · BSH Drives and Pumps, s. r. o. · CERAM ČAB, a. s. · CERTOS s. r. o. ·ContiTech Vibration Control, s. r. o. · DAEWOO AVIA, a. s. . · Daimler Chrysler · Delta - ML, s. r. o. · Drôtovňa Drôty, a. s. ·
DRU, a. s. · DURA Automotive Systems · Duropack Turpak Obaly, a. s. · ELBA, a. s. · Elektrokarbón, a. s. · EMBRACO SLOVAKIA, s. r. o. · Emerson, a. s. · Emerson Electric SLOVAKIA, s. r. o. · ETA, a. s. Hlinsko · Faurecia Bratislava · F B E
Bratislava, s. r. o. · FLOTT SLOVAKIA, s. r. o. · GEMOR Fashion, s. r. o. · HELLA Autotechnik · s. r. o. · Hriňovskéstrojárne, a. s. · HUMUSOFT, spol. s r. o. · HYDRONIKA DEE, a. s. · Hygiene Products, spol. s r. o. · ICOS, a. s. Košice ·I.D.C. Holding, a. s. · INA SKALICA, spol. s r. o. · INERGY Automotive Systems Slovakia, s. r. o. · InsData, spol. s r.o. ·
Invensys Metering Systems, a. s. · Istrochem, a. s. · IQvolutions · IVAX Corp.. · Jeska, a. s. · JOARR s.r.o . · JohnsManville . · KALCIT, spol. s r. o. · KASTEK UB, spol. s r. o. · KINEX – KLF, a. s. · KNOTT, spol. s r. o. · KONŠTRUKTA -Industry, akciová spoločnosť · KŘIŽÍK, a. s. · KROMBERG & Schubert, s. r. o. · Leoni Autokabel Slowakia, spol. s r. o. ·Leoni Slowakia, s r.o. · MATADOR a.s. Púchov · MERINA, a. s. · MIBRA, spol. s r. o. · MKEM, spol. s r. o. · Novácke
chemické závody, a. s. · Neografia Martin . · NOVING NOVÁKY, spol. s r. o., Opel AG · OSTROJ Opava, a. s. · Peviz, spol. s r. o. · Plastic Omnium Auto Exteriors, s. r. o. · PosAm Bratislava, spol. s r. o. · POTRAVINÁRSKE STROJÁRNE SVIDNÍK,
a. s. · PRECIOSA INTERNATIONAL, spol. s r. o. . · Prefa Brno . · PSL, a. s. · QUILTEX, spol. s r. o. · RautenbachSlovakia. · RAMEX, a. s. · RIBE Slovakia, k. s. · Saint-Gobain Sekurit ČR, spol. s r. o. · SANKER, spol. s r. o. · Sauer -
Danfoss, a. s. · SCA Hygiene Products, spol. s r. o. · SCP Neusiedler, a. s. · SHP Harmanec, a. s. · Siemens Automotive, s. r. o. · Siemens Business Services, s. r. o. · · Slovenská strojárska spoločnosť, Bratislava · SLOVMAG, a. s. Lubeník · SMC
Pneumatik GmbH · SOFTIP SEVER, a. s. · SOVA, a. s. · SPP, a.s. . · OZ Žilina · STEAG Electronics . · SwedwoodSlovakia, s.r.o. · Škoda Auto a.s. · TAURIS, a. s. · Team Industries . · TESLA STROPKOV . · Teslamp a.s . · a.s ·
TEXIPLAST, a. s. · THORMA Výroba, k. s. · TI GROUP AUTOMOTIVE SYSTEMS, s. r. o. · TRANZA, a. s. ·TurboConsult, s. r. o. · U. S. Steel Košice, s. r. o. · VAP, a. s. Prešov · VIAX Solutions · VIPO a. s. · VÍTKOVICE, a. s. ·
VOJUS, a. s. · Volkswagen Elektrické Systémy, s. r. o. · VOLKSWAGEN SLOVAKIA, a.s. · VSS, a. s. Košice · VUMA a. s., Liebert HIROSS · VUNAR, a. s. · WOIS Institute Slovakia · Yazaki Slovakia, spol. s r. o. · YMS, a. s. · ZSNP, a. s. ·
Železiarne Podbrezová, a. s. · ŽOS Trnava, a. s. · ŽOS - VÝVOJ, s. r. o. Vrútky
Some Customers from Slovakia and the Czech Republic
8
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
TRIZTOC
Systematic Innovation
WOIS
Lean Management
TOC
FMEA TQM
Kaizen
Six Sigma
=
Customer Benefits (Useful Functions)
Costs + Harmful Functions
Customer Value
Customer Value Increase
9
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Contradiction –Development Barrier
New Solutions –Contradiction Solution Principles, Variation and Combination, Final Solution
Orientation - Strategy, Trend Analysis, Current State Analysis, Evolution Trends, Ideal Solution
Spiral of Evolution
Contradiction based innovation strategy
Source: H.Linde, WOIS
10
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Segment 1 Segment 2
Market
Customer processes
Needs, requirements
Mar
ket
S egm
ents
Cus
tom
ers
Nee
d s
Nurse PatientTechnican
Manager Doctor
Segment - EU Thomas Decket Sabine Ludger T.Hartman Belgium Belgium International Netherlands Kim Netherlands Priemer Poradie MOBILIZACE PACIENTA
5 5 5 4 5 5 5 5 5(5) 5 4,9 2
TRANSPORT PACIENTA
5 4 5 4 3 3 4 5 4(5) 4 4,1 9
REHABILITACE PACIENTA NA LŮŽKU
4 3 3 2 2outside of the bed
3 2 4 3(3) 3 2,9 15
HYGIENA PACIENTA
3 4 5 2 4 4 2 5 5(5) 3 3,7 12
KOMFORT PACIENTA
3 4 2 2 4 4 3 5 has control over
movements, sorrouding
3(3) 5 3,5 13
BEZPEČNOST PACIENTA
5 5 5 5 5 5 5 5 5(5) 5 5,0 1
PŘÍSLUŠENSTVÍ 4 5 4 4 5 4 5 5 5(5) 5 4,6 5 OSTATNÍ MANIPULACE S PACIENTEM
3 3 4 4 4 5 5 4 5(4) 5 3,2 14
MANIPULACE S LŮŽKEM
5 5 4 4 5 5 5 5 5(4) 5 4,8 3
POLOHOVÁNÍ PACIENTA
5 4 4 4 4 5 5 4 4(4) 5 4,4 6
VZHLED LŮŽKA 4 4 2 3 5 4 5 4 4(4) 4 3,9 10 OVLÁDÁNÍ, ERGONOMIE
4 4 4 5 4 5 4 5 3(3) 4 4,2 8
HYGIENA LŮŽKA 4 5 5 4 5 5 5 4 4(4) 4 4,5 4 BEZPEČNOST SESTRY
4 4 5 3 4 4 5 5 4(4) 5 4,3 7
KOMPATIBILITA MATRACE, LŮŽKA A LŮŽKOVIN
4 3 4 3 3 4 5 4 4(4) 4 3,8 11
RYCHLÝ SERVIS, 5 5 4 4 5 4 5 4 4(4) 5 4,5 4
ProcessesO1= Handling with patientO2 = Handling with bedO3 = TransportO4 = Adjustment, setupO5= Connection with environmentO6= Work with accessoriesO7= Ensuring safetyO8= Mattress handlingO9= Design-interaction with product
O1= Handling with patientO11 = patient examination: CT, RTGO12 = moving patient onto other bedO13 = patient positioningO14 = turning patientO15 = patient mobilisationO16 = handling during urinateO17 = changing clothesO18 = patient hygieneO19 = eatingO20 = re-dressingO21 = changing mattressO22 = changing bed clothesO23 = adjusting patient positions
Orientation
11
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Lean Logistics– SCM, Partnership
with Suppliers, VSM, TPM, Standardisation,
Kaizen, Quality in Process,Logistical Network
Optimisation
Lean Production– Lean Workplace,
visualisation, VSM, Pull, Kaizen, TPM, SMED, Manufacturing Cells,
Team Work, Quality in Process, LCA
Lean ProductDevelopment
– Set Based Thinking, VSM, DFMA, VA, Project
Management, Team Workand Simultaneous
Engineering, Quality and Visualisation,
Kaizen
Lean Office – 5S, Time and Meeting
Management, VSM, Quality in Process,Kaizen, Standardisation
and Visualisation, Team Work
Knowledge Managementand Development
of Corporate Culture- Continuous Development
and Visualisation of Knowledge- Non Blaming Culture- People Involvement
- Continuous Improvement
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Lean
SixSigma
TOCThroughput
Increase
Waste Reduction
Process Variability Reduction
ProductiveProcesses
EfficientProcesses
StableProcesses
SatisfiedCustomers,
Stockholdersand
Employees
CustomerValue
Specification
Lean – Six Sigma – TOC?
13
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
TOCBottlenecks and Throughput
Increase
LEANWaste Elimination from
the Processes Six Sigma
Process Variability Reduction and Process
Stabilisation
Problem solving
15
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Our Innovations- Vacuum cleaner
- Shaving machine
- Gear box
- Cylinder head
- Furniture
- Hospital bed
- Cutting machine
- Jack
- Mower
- Lock
16
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Project steps1. Market analysis- Customer requirements- Analysis of competitors- Development trends
2. Product analysis- Structure- Functions- Parameters- Costs
3. Innovation process- Add required functions- Eliminate not required
functions- Improve required
parameters- Solve contradictions
4. Implementation- Product design- Testing- Production- Marketing/ Sales- Evaluation
17
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
QualityProcesses
QualityProcesses
TPMTPM
SMED andBatch SizeReduction
SMED andBatch SizeReduction
StandardizedWork, Operation
Standard Procedures
StandardizedWork, Operation
Standard Procedures
ValueStream
Mapping
ValueStream
Mapping
Kanban, Pull,SynchronisedMaterial Flow
Kanban, Pull,SynchronisedMaterial Flow
5S and Visual
Management
Lean Layout,Manufacturing
Cells
ContinuousProcess
ImprovementKaizen
Team Work
Lean Production
CustomerOrder
Waste ProductShipmentProduct
Shipment
Time
Business as Usual
CustomerOrder
ProductShipment
Time (Much Shorter)
Waste
Lean Manufacturing
CustomerOrder
ProductShipmentProduct
Shipment
Time (Much Shorter)
Waste
Lean Manufacturing
18
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Tools
Process map
Palette
Working place
•Systematic Organization (SEIRI – sifting)
•Sorting (SEITON – sorting)
•Scrubbing Clean (SEISO – sweeping)
•Standardizing (SIKETSU – standardize)
•Self-Discipline (SHITSUKE – sustain)
5S
Classification1. Assessory2. Tools/Fixtures3. Measure Eq.4. Raw material5. Component
6. WIP7. Final product8. Office material9. Documentation
Red Tag
Item/Nr
Quantity
Reason
Department
Name/Date
Nr ___
5S and Visual
Management
19
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.skValueStream
Mapping
ValueStream
Mapping
Value Stream Mapping – VSM: The drawing of a visual representation of every process in the (customer to supplier) material and information flow of a defined product family. It forms the basis of an implementation plan through the depiction of an ideal “future state” value flow
20
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Nine Types of Waste
–Over production
–Delays
–Transportation
–Process
–Inventories
–Motions
–Defective products
–Untapped resources
–Misused resources
ContinuousProcess
ImprovementKaizen
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
31
Single Piece Flow = WIP
Supply ofComponents
Raw Materials
Cle
ar F
loor
spa
ce
Produce to TAKTCustomer Pull
Balanced Work
Supply ofComponents
Ergonomics Late Configuration
Lean Layout,Manufacturing
Cells
vo.hi.
ca. 2
000
1100
Maß: 460x340x155
A B112233
B1A0
B2BK1BK2A2A1A3A4A0A0
AK1AK2AK3AK4AK5 AK6AK7
A0
22
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
TPM
Maintenance organisation, information system
OEE Program
Autono-mous
mainte-nance
Planned mainte-nance
Training program
Early Equipment
Manage-ment for
new machines and parts
• denne
• týždenne
• mesačne
Č. Prvok stroja Int. Mazadlo Množstvo Metóda Kto?
MAZACIA KARTA ZARIADENIA Názov zariadenia Kalička Rok výro by Inv. č ís lo 174-175
Výrobca EFDGH Elektote rmia V prevádzke od Oddelenie 02M
Typ T - 647 Výr. č íslo Miesto MT M1
Druh práce Opakovano sť Príklad N = Namazať event . doplniť h = hod in ová P+N/m = Preveriť + Na ma zať e vent. Do plniť / me sačne P = Preve riť d = den ná VČ / 5r = Výmena Čis te nie / 5 ročn e Č = Čis t iť t = týžd enn á V = Výmena m = mesačn á
r = ročn á
Mazacie mies to Mazacie p rá ce Ma za cí pros tried okČis lo Poče t Die l za ria den ia Druh práce Opakova nosť Ma t.č. Množstvo-l/kg Pozn ámka
1 1 Centrá lne mazanie N t 0039 2,7 L Renep 2K, VG 68
TPMTPM
23
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Čistenie16%
Ostatné6%
Nastavenieprogramu
4%
Výmenanástrojov
32%
Štúdiumdokumentácie
8%
Nastaveniečeľustí,
podložiek a úpiniek
34%
SMED andBatch SizeReduction
SMED andBatch SizeReduction
0,0% 10,0% 20,0% 30,0% 40,0% 50,0% 60,0% 70,0% 80,0% 90,0% 100,0%
Internal activities
External activities
Activities performed when machine is switch off Setup activities when machine is running
1. Preparation for setup
2. Assembly and disassembly
3. Setting, adjusting
4. Waiting for starting production
24
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
StandardizedWork, Operation
Standard Procedures
StandardizedWork, Operation
Standard Procedures
Váha
Páskovač
10 -
15 c
m
41 c
m
68 cm
28 cm
25 c
m
32 c
m
37 cm
A B
Miesto pre umiestnenie
kartonovníka a etiketovačky
25
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
§Source Inspection: Operators must be certain that the product they are passing to the next work station is of acceptable quality. §Operators must be given the means to perform inspection at the source, before they pass it along. §Samples or established standards are visible tools that can be used in the cell for such purposes. §Process documentation defining quality inspection requirements for each work station may need to be developed.
QualityProcesses
QualityProcesses
Assy.Instruct.
Freq
uenc
y
Design Purch.Training
Other
970
980
990
1000
1010
1020
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LCLLCL
UCLUCL
Freq
uenc
y
Data Ranges
EffectEffect
ManMachine
MaterialMethod
Environment
ManMachine ManMachine
MaterialMethod
Environment
1. Plan1. Plan
2. Do2. Do3. Check3. Check
4. Act
Billing Errors
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
0.440.460.48
0.50.520.540.560.58
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Dia
met
er
EFQMEFQM
26
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
123
124
125
126
127
128
129
130
131
132
133
134
135
Po Ut St Št
876543210
Zakázky
136
WorkshopyWorkshopy SegmentáciaSegmentácia
Nástroje kvality
Nástroje kvality
Tímovápráca
Tímovápráca
Kanban tabuľa
Materiál
..............
..............
..............
Červená zóna Zelená zónaŽltá zóna
Kanban, Pull,SynchronisedMaterial Flow
Kanban, Pull,SynchronisedMaterial Flow
27
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Vedúci SHP
Majstri TL Majstri VA
Tím1
Tím2
Tím3
Tím4
Tím1
Tím2
Tím3
Tím4
Tím1
Tím2
Tím3
Tím4
Tím1
Tím2
Tím3
Tím1
Tím2
Tím3
Tím4
Tím1
Tím2
Tím3
Tím4
Striedači
Správa strediska
Hlavný technológ
Technológ
Technológ
Prev. účtovník
Ekonóm
Účtovníkskladník
Business Tím VABusiness Tím TL-CBusiness Tím TL-B
Business Tím TL-D Business Tím TL-D
Servisný tím
Team Work
28
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Project management structure
Local decision teamSponsors
Project Managers (PM)
Specialists = Method Owners
Team Members
Externalconsultant
29
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Lean sigma concept
6 Sigma – methodology focused on the stabile, robust and high reliable processes with 6 Sigma parameters and DMAIC
approach
Lean conceptoriented on the
systematicidentification and
systematicelimination of theall forms of waste
and maximum streamline of the
processesProject management and team work – orientation
on the goals and theprocess of their
achieving
σ
30
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Participants on the Seminars and Trainings• ST - Students and Uni-Graduates – 20-30 / year• TM - Top Management from SMEs• SM – Middle Management• MT – Supervisors, Team Leaders, Team Members• TH – Process Planning, Industrial Engineering,
Product Design and Development• MF – Owners of the companies
FieldsMechanical Engineering – Automotive – Chemie – FoodIndustry – Electrical Engineering – Medical Technology
31
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Education Forms
• IS – Information and discussion seminars and workshops – 1-2 days
• PV – Project oriented Study – Students – 6 – 12 months, 4-8 days/ month
• MS – Master study – 24 months, 4–8 days / month
• PS – Postgraduate study with certification – 1 year, 4-8 days/ month
• KS – Compact study – 10 – 16 days
• BT – Block training– 2-5 days
• KA – Coaching
• TT – Training of Trainers with licence
32
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Products
5TM, SM, MT, THBTTheory of Constraints
BT
BT
BT/KA
PS/KS
KS
KS
PS/KS
PS/KS
BT/KA
PS/KS
KS
MS
Form
10MT, THErgonomics
5TM, SM, MT, THProject Management
10-12TM, SM, MT, THEffective Communikation Skills
24TM, SM, MT, THIndustrial Engineering
10-12THInnovations and Creativity
10-12TM, SM, MT, THChange Management
24-40THLean/Six Sigma – green belts, black belts
24MT, SMSupervisor Academy
24MT, SMTeam Work
30-40THProduct Design and Process Planning
10-12TM, SM, MT, THLean Academy
75-80TM, SM, MT, THInternationalam Master Study (MEng) – Industrial Engineering and Logistics
DaysParticipatnsProduct
33
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Products
5TM, SM, MT, THBTContinuous Process Improvement, Kaizen activities
BT
BT
BT
KS
BT
BT
PS/KS
BT
BT
KS
KS
BT/KS
Form
5TM, SM, MT, THDesign for Manufacturing and Assembly
5TM, SM, MT, THSimulation und Virtual Reality
2-4TM, SM, MT, THOutdoor Training
24-40TM, SM, MT, THTRIZ and WOIS Methodology
5TM, SM, MT, THTraining of Trainers
5TM, SM, MT, THValue Stream Management
24-40THTraning of Lean Methods – 5S, Kanban, LCIA, SMED, OPF...
10MT, SM, THProduction Planning and Control
5-10MT, SM, THWork Analysis and Measurement
10THManufacturing Systems Design and Layout Planning
10TM, SM, MT, THLogistics
5-10SM, MT, THTPM
DaysParticipantsProduct
34
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Top Management
Management Training – Foreign Languages – OutdoorTeam Building Trainings – Strategic Workshops –
International Master Study
MiddleManagement
SupervisorsTeam Leaders
Workers
International Master Study – Specialised Trainings –Lean, SixSigma, Industrial Engineering, Logistics,
TPM, Team Work, Foreign Languages
Supervisor Training Academy
Simple Lessons – Lean, Kaizen, Problem Solving Workshops
35
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Training Coaching
ConsultingLecturing
Knowledge
Solving realsituations in the company
Solving casestudies
Practical Skills
Forms of education
36
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Management Education - International Master Degree
Fachhochschule Ulm
Fraunhofer InstitutProduktionstechnik undAutomatisierung
IPA
2 years study – certified
MEng Diploma
Industrial Engineering and Logistics
37
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Management Trainings
Team Building – Strategic Workshops– Communication Skills – Conflict
Solving – Change Management – SixSigma – Lean Processes – Assesment
Centres
2-3 Days
38
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Typical Training Topics for Middle Management
• Project Management
• Team Work and Communication Skills
• Process Improvement and Problem Solving Methods
• Lean/Six Sigma Tools
• Industrial Engineering
• Logistics
• Process Organisation and Standardisation
• Work Analysis and Measurement
• TPM
• Quality Processes
Industrial
Engineering
Inside
39
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Supervisor Training Academy – 24 Days• Supervisor´s process responsibility
• Team work
• Work Measurement and Process Standardisation
• Communication and Presentation Skills
• TPM and SMED
• TQM and Six Sigma Tools, DMAIC
• Process Planning and Control
• Work Place design and Optimisation
• Visual Management
• Process Improvement – Kaizen, PDCA
• Workshop Organisation and Moderation
• Project management
• Time Management
• Layout Planning
• Industrial Engineering Tools
40
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Typical One Point Lessons for the Workers• 5S
• TPM
• SMED
• Visual Management
• Work Standardisation, Standard Operation Procedures
• 7/7 Quality Methods
• Team Work
• Work Analysis and Measurement
• Kaizen
• Workshops
• Self Responsibility
• Work Place Organisation
• Problem Solving Process
41
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
• Basic information – overview• Case study• Practical example• Discussion and feedback• Each participant should have own practical project from the
factory for practical testing and training of the IE methods• Lecturers give the participants also individual support –
coaching, consulting, information sources• Lecturers give after each module feedback to the top
management • Each participant will receive text-books and learning materials
on CD ROM
Principles of Training
42
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Training project – progress proposal
• Meeting with management – discussion of the detail contents and volume of each module – 4 hours
• Introduction test and workshop with participants – testing basic knowledge, education and experience level, real training needs –4 hours
• Final training program proposal
• Start of training / training is combined with solving practical problems in the company– lecturers give support to the participants
• Final tests and presentation of the project results
• Evaluation of the program, graduation of participants by certificate
• Defining new projects for each participant
43
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
References of IE long term trainings in Slovakia/ Czech republic
PSL/Thysen Krupp – Steag Electronics – Vacuumschmelze –ROCO – Doka Slovakia – Rautenbach – Volkswagen – Boge -Ceram Čab – Kuester – Tranza – Linet – SPP – IDC Holding –Ribe - Sauer Danfoss – Siemens – IKEA - Bonatrans – Elba –
Hella Autotechnik – Visteon – Zetor – Johns Manville – Leoni –Matador – Continental – ZF Sachs
References about the training of lecturers of IPA
Mike Rother – Lean Institute (VSM) – Ted Hutchin – A.Goldratt Institute (TOC) – Fraunhofer IPA Stuttgart – FH Ulm – Nottingham Trent University – KaizenInstitute – Lanner Group – Cognos, International Change ManagementTraining, Training of Trainers, etc
44
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Teaching materials
CD ROM Toolbox
45
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Training materials
- more than 600 books
- CDROMs, DVD
- Video
- Toolboxes
- Training games
- Case studies
- Projects
- Simulation games
- Handouts
- Prezentations
- Forms
46
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
ToolboxyToolboxes
47
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
Náš prístup
Náš tím v Žiline
48
Slovakia
IPA Slovakia Žilina + Fraunhofer IPA Stuttgart
www.ipaslovakia.sk
IPA Slovakia – more than 300 successful trainingprogrammes and projects
IPA Slovakia, www.ipaslovakia.sk
Veľký Diel 3323, 010 08 Žilina
Tel.: 041-5686-426, 0903-500054,
Fax.: 00421-41-562915