Skarbimierz Gum. Driving Competitiveness Event May 29 th, Dublin Castle, Ireland

Transcription

1 Skarbimierz Gum Driving Competitiveness Event May 29 th, Dublin Castle, Ireland

2 A Brief History April 2013 February 2010

3 Location on European Map Skarbimierz, Poland 60 km from Wrocław

4 Skarbimierz Gum Facility Production Commenced 2009 Factory occupies c.13 hectares Floor area of Factory 28,000 m2 380 Employees

5 Product s

6 Business Environment Complexity V s Volume Reductions FG SKU volume (k T)

7 Environment Business Increasing product Complexity Shorter productions runs Increasing Equipment changeovers Changeovers adversely affecting Line Efficiencies Site CI seen as an additional task CI Fatigue Lean Tool Confusion Lack of Consistency in Lean tool execution Increased distractions from what mattered

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10 Five Bold Steps QUALITY OWNERSHIP ENGAGEMENT Not full capacity Org. will help Irish boss Willingness to Nothing to lose learn Formatting the People we have organization WE have created IT Change of Org NAME THREATS BIGGER PURPOSE SHARING KNOWLEDGE & BENCHMARK No arguments (no info to employees, no support, no benefit) Passive (lack of collaboration, be a passive participant, no risk management, lack of engagement VISION The most successful Gum site where people are inspired to fulfill Customers and Business needs OPEN COMMUNI- CATION SUPPLIER OF CHOICE Revisit Vision & KPI Include Vision in Yearly Plan Spread the Vision Define & Map The Method of Implementation (skills & process) Buy-in Change Agents (critical mass) BOLD STEPS Do nothing (stop here; let the time pass) Changing the leader Wrong communication (no proper attention to Focus on short term only vision, not talking about it, no alignment)no ownership (by FLT, no identification with vision It s our vision You implement it especially Mgrs & FLT)

11 Site Vision

12 Repetitive Flexible Supply

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14 We can do Anything But We cannot do Everything!

15 We Need A Plan

16 CI Roadmap Performance Objective Waste 27%Sl 2,7% Slabs Waste reduction Slabs Waste reduction Slabs Waste 3% Sticks Waste reduction Sticks Waste reduction Sticks GE Improvement GE improvement GE improvement Power of Performance Initiatives SMED on 12 & 16 lines and Loesch lines Waste Reduction to 2,7% on Slabs. Overweight reduction to 2% on pellets. 3 Sigma measurement of Loesch lines, 12 & 16 Lines Pull System implementation on Slabs 5S on all lines Waterspider (Milk run) for packaging TPM audit & AM on pilot line POM implementation SMED on Sapal lines 3 Sigma certification of Loesch, 12 & 16 Lines 3 Sigma mesurement of Sapal lines, FM lines & I-box lines Waste Reduction Overweight Reduction TPM continuation POM implementation TPM continuation 3 Sigma certification of Sapal lines, FM lines & I-box lines Waste Reduction Overweight Reduction TPM continuation POM implementation Leadership Development Power of One CI Resources Daily production meetings Benchmarking visits continuation Benchmarking visits continuation Join Lean & 6S conferences Join Lean & 6S conferences Join Lean & 6S conferences Lead 2 Kaizen Events Lead 2 Kaizen Events Lead 2 Kaizen Events TPM in Lean Academy Internal coaches development Develop CI library Internal coaches development Develop CI library Develop CI library Benchmarking visits in 6 plants A3 problem solving method development 2 Kaizen events Host of CI Gum event A3 problem solving method development 2 Kaizen events 16 A3 problem solving method development 2 Kaizen events 2 BB, 5 GB, 15 SGA leaders 2 BB, 7 GB, 25 SGA leaders 2 BB, 7 GB, 25 SGA leaders

17 Lean Academy 2013 Time of Internal Trainers! Goals: Short term: Create standards and transfer of good knowledge between operators and technicians, create skills matrix with clear responsibilities Long term: GE improvement Area: Loesch Lines I stage: Recruitment process for operators - 15 people applied! - done II stage: Train-the-trainer course and people selection in progress III stage: Create skills matrix For whom: Technicians Operators Team leaders

18 Lean Academy Trainings Lean Manufacturing basics Internal trainers academy Small Group Activities Dates SMED Heijunka Problem Solving Temat szkolenia Marzec Kwiecień Maj Czerwiec Lipiec Sierpień Lean Manufacturing basics Tydzień 18 TPM Problem solving Tydzień 10 Tydzień 22 Tydzień 27 [ SGA, A3 ] TPM Tydzień 15 Tydzień 24 SMED Tydzień 12 Tydzień 35 Internal trainers academy Tydzień 16 Tydzień 24 lub Tydzień 32 lub Heijunka Tydzień 21 Tydzień 34

19 Global Line Efficiency Global l Efficiency i (GE) Measurement of asset capacity utilization calculated as a ratio of the actual product produced to the theoretically possible amount of product that could be produced during the theoretical hours minus the No Demand and Legal Holiday hours. 19

20 CI Projects Main Lean/Kaizen & 6Sigma projects Finished: Started: In Progress: In Progress: Started: In Progress: Coaters Cleaning time stabilisation (135 mins) Waste level reduction on Slabs Changover time reduction by 50% on O Hara lines Overweight reduction on Pellets Overweight reduction on Slabs Waste reduction on LTM machines Bożena Socha Klaudia Libner- Łukaszenia Marcin Borowski Magda Karabowicz Ala Jastrząb Piotr Żurawski Target: Target: Target: Target: Reduction from 5% to 3,5% Average Reduction from 3% to 2,25% Average Reduction from 2,05% to 1%; Reduction by 20% Lean/Kaizen Projects 6 Sigma Projects

21 Talk Reduction (16 Line) - Kaizens A Losses Identification Losses Elimination Before After

22 CI SMED Activities 12 Line 16 Line Loesch Lines Time reduction for 130 minutes Time reduction for 180 minutes changeovers in 12 line can be changovers in 16 line can be Changeover on Loesch from 18 to 12 reduced by 43 % reduced by 50% format 86 % time reduction % % % % 86 % Current state SOP Current state observed Future state Timing: 31st of January 2013 Current Current Future Future state state state state SOP observed Step 1 Step 2 ~ 131 kpln savings ~ 153 kpln savings Timing: 31st of December 2012 Current Current Future Future state SOP state state state observed Step 1 Step 2 ~ 156 kpln savings Timing: 31st of December

23 Utilities m3/t Water Unit Consumption ,0% m3/t Water CON-10Water CON-11Water CON-12Water CON Effluent Unit Consumption ,0% Effl. CON-10 Effl. CON-11 Effl. CON-12 Effl. CON-13

24 Benchmarking Visits 2013 Kaizen Institute Conference Today September October November January March May July Poznańń Open training Kaizen Basics

25 Not the End, only a Pause