Lean Warehousing at Bosch

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Bartholomew Lester
7 years ago
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1 Lean Warehousing at Bosch Yinglan Zheng Project Manager Corporate Sector Purchasing and Logistics Asia Pacific 1

2 Agenda Warehousing at Bosch Bosch experience with warehouses Definition of Lean Management in the Bosch Logistics Lean Management activities in Bosch Warehouses Results of Lean Management activities in Bosch Warehouses 2

3 Warehousing at Bosch 800 Warehouses covering over 2 million m² 285 plants with internal LO* across 46 countries several hundred million EUR cost Many LO with no productivity measurement ~150 different IT systems associates Complex warehousing; high potential for improvement 3 * LO = Logistics Operations

4 Agenda Warehousing at Bosch Bosch experience with warehouses Definition of Lean Management in the Bosch Logistics Lean Management activities in Bosch Warehouses Results of Lean Management activities in Bosch Warehouses 4

5 Bosch experience with warehouses Performance of warehouses doesn't show further significant improvements one year after go live Relevant KPIs are not often existing or measured sporadically (less than daily) Improvement activities are carried out sporadically, often derived from employee suggestions (not from KPI targets) Good Practice exchange is not often existing among warehouses Standardized training for new employees does not often exist In most warehouses Lean Management is not yet implemented! 5

6 Agenda Warehousing at Bosch Bosch experience with warehouses Definition of Lean Management in the Bosch Logistics Lean Management activities in Bosch Warehouses Results of Lean Management activities in Bosch Warehouses 6

7 What does Lean Management mean for Bosch Logistics? Lean Management is a leadership concept for us With the goal of sustainable, measurable improvement of processes Therefore it is necessary to monitor the performance in a high frequency and systematically analyze and improve all processes This happens with the involvement of all employees To reach that we use: System-CIP for Process- / Value Stream Design Point-CIP for process stabilization and improvement Lean Management is in the responsibility of all leaders 7

8 Agenda Warehousing at Bosch Bosch experience with warehouses Definition of Lean Management in the Bosch Logistics Lean Management activities in Bosch Warehouses Results of Lean Management activities in Bosch Warehouses 8

9 Project structure of Warehouse Excellence System- and Point-CIP are derived from production Set up Warehouse Excellence project to prove that the same principles also work in a warehouse environment BOSCH participants: AA /PT Denham AE Reutlingen, Salzgitter CC Lica, CM Braga DS Homburg, Jilhava DC Laatzen (DC-IAP) LSP* participants: AA/PT Wroclaw (LSP) CM Hildesheim (LSP) DC Witten (LSP) GS RBCB (LSP), Waiblingen (LSP) PT Derendingen (LSP) TT Hamburg (LSP), Ingolstadt (LSP) *LSP= Logistics Service Provider 17 warehouses, 10 GB and 6 LSP* across 7 countries 9

10 Good Practice Transfer of the BVL-AK-LML* Transport Logistic China 2012 Project structure of Warehouse Excellence Bosch Logistics Workshops (BLW) System-CIP, Point-CIP and the role of the leader Mix of theory and practical doing in a training warehouse Participants: Mix of Bosch and Logistic Service Provider Employees Bosch Logistics Learning Group (BLLG) Lead learning groups with the purpose of enabling each other Rotational visits of different warehouses Participants: Mix of Bosch and Logistic Service Provider employees Bosch Interdisciplinary Local Teams (BILT) BPS-Experts coach at the side of the warehouse manager Supporting implementation Know How of BPS and leading aspects The enabling concept has four elements *Bundesvereinigung Logistik- Arbeitskreis-Lean Management in Lägern 10

11 Milestones of Warehouse Excellence Bosch Logistics Workshop I (BLW) Milestone I VSM/VSD project plan Milestone II Regular Com. Visualisation BLW II Milestone III Point CIP Training of employees BLW III Project end Evaluation Bosch Logistics Learning Group (BLLG) BLLG BLLG BLLG BLLG Bosch Interdisciplinary Local Teams (BILT) Bundesvereinigung Logistik Arbeitskreis Lean Management in Lägern 09/10 11/10 01/11 03/11 05/11 07/11 09/11 11/11 t 11

12 Agenda Warehousing at Bosch Bosch experience with warehouses Definition of Lean Management in the Bosch Logistics Lean Management activities in Bosch Warehouses Results of Lean Management activities in Bosch Warehouses 12

13 Soft results To enforce LEAN in warehouses is now in the focus! Logistic Service Providers are now understanding better what Bosch means with continuous improvement process Several Logistic Service Providers have set up new lean departments in 2011 in order to drive lean into their organization In 2010 two Bosch service providers had a lean assessment In 2012 four Bosch service providers have a lean assessment and two other are working to establish one It s slowly rolling but we are still at the beginning of the way to excellence! 13

14 Key Takeaways Lean Management is about the implementation of a KPI-oriented, continuous improvement process guided by the manager. In most warehouses Lean Management has not yet been implemented! 3. Warehouse Excellence is the pilot project with the target to prove that Lean Management also improves Q, C, D in warehouses. 4. Warehouse Excellence proved the effectiveness of Lean Management in warehouses. Warehouse Excellence showed the success with speed! 14

Technik vs. Lean: Widerspruch oder Ergänzung

LOGISTIK HEUTE Forum auf der CeMAT 2008 Hannover, 28. Mai 2008 Technik vs. Lean: Widerspruch oder Ergänzung Vortrag im Rahmen des Forums: Warehousing Prozesse und Technologien mit Lean Production-Konzepten