BSH Production System
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1 BSH Production System Festo Didactic 2. März Kolloquium Nachhaltige Kapazitätssteigerungen in manuellen Montagesystemen festo didactic_exh_932
2 Das Ziel war Ebene der Leistungs - Steigerung Einführung des FNW PS Produktivitätssteigerung 1. Ebene der Leistungs - steigerung BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 2
3 Increase of factory output capacity BSH Production System Demand oriented production Robust product phase-in / phase-out Challenging and fostering our people Avoiding defects (zero defects) Avoiding waste Pull-principle ABC/XYZ-Analysis JIT/JIS Kanban Milk run Supermarket Vendor Managed Inventory Customer takt One-piece-flow Production smoothing and leveling Quick changeover Value stream mapping/ design Procurement management Make or Buy Procurement marketing & supplier selection Supplier integration Supplier management Phase-in / phase-out management Variants management and ECO Production order release Project management Planning guideline Resource and time planning Risk and escalation management Product development process (PEP) see PEP guideline = principle Teamwork Human relations barometer Team briefing Responsibility matrix Employee qualification and development Country specific tools Performance orientation Country specific tools Defect prevention FMEA Poka Yoke SPC Defect detection / test planning Line stop concept Product audit Testing Worker self check Reliability tests Defect analysis / correction Complete FPY recording Field failure analysis Quality feedback loops Analysis of returns Standardisation and Sustainability = method 6 - SIGMA = tool Standardized work Work place organization (5S) Standard operating sheet Total Productive Maintenance (TPM) Visual management KPI management Labeling and markings CIP Problem solving techniques Improvement workshops BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 3
4 Value stream mapping and design Value stream mapping (65 units/ 8h) Value stream design (85 units/ 8h) Required process improvements developed (lead time and inventory reduced, processes synchronised) Tactical implementation plan defined Improvement teams are continuously developing, evaluating, optimising and reviewing (> 2 measures) BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie:
5 ,25,5,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75,25,5,75 5 5,25 5,5 5,75 6,25,5,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75,25,5,75 5 5,25 5,5 5,75 6 6,25 6,5 6,75 7 7,25 7,5 7,75 8,25,5,75 9 1,25 1,5,25,5,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5,25 3,75,5,75,25 1,51,25,751,5 5 1,75 5,25 2 5,52,25 5,752,5 62,75 6,25 3 6,53,25 6,753,5 73,75 7,25 7,5,25 7,75,5 8,75,25 5,55,25,755,5 15,75 1,25 6 1,56,25 6,5 6,75 7 7,25 7,5 7,75 8,25,5,75 9 1,25 1,5,25,5,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75,25,5,75 5 5,25 5,5 5,75 6,25,5,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75,25,5,75 5 5,25 5,5 5,75 6 6,25 6,5 6,75 7 7,25 7,5 7,75 8,25,5,75 1 1,25 1,5 h Standardised work Work flows were recorded and analysed with employee involvement Work stations, walking times and tools have been optimised A cycle time bar chart is available in each group NTC D-Buchse 5 Heizkörper Motor Steuerung Schraube Schraube Schelle Geberschlauch/ 5 Riemen gehäuse 3 5/1 Geberschlauch Magnethalter Gebergehäuse Arbeitsplatzoptimierung: Layout, Materialbereitstellung, Wege D-Buchse KLT KLT Motor Motor Arbeitsplatzoptimierung: Layout, Materialbereitstellung, Wege AS152 AS15 AS18 Steuerung Schraube NTC Schelle Magnethalter 9/65 35 D-Buchse Geberschlauch/ 2 5 gehäuse Riemen Motor 5/1 5 x Magnethalter 9/65 D-Buchse 2 / 8 Kg/Karton Vormontage Bereitstellungswagen Motor FDM All work contents are highlighted as value added work, semi-value added work, waste or logistic activities The standard operating sheets are available and accessible at the work stations Schraube Springer - Aufgaben: - Wechsel der Palette Motore - Auslösen Staplerruf - Austausch 2. Wagen Magnethalter - Öffnen der Kartons und PP-Bänder entfernen Motor - Zwischenpuffer (Motore) auffüllen Motor Pappe/Mo - Zwischenlage Motorenverpackung tor - Austausch der Paletten (Heizkörper/Reibdämpfer) BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 5
6 Supermarket and Milk-Run The Supermarket provides the defined minimum and maximum quantities of raw materials for the production process (6 spaces for palettes, small parts warehouse, repacking area) Kanban controls the information flow and regulates the material supply between the supermarket and the assembly line Milk runs supply materials along a defined route at predetermined times, fixed quantities and compositions (internal round-trip cycle 1 hour) BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 6
7 Totale Productive Maintenance TPM maintenance- and cleaning instructions are visualised at the machines and equipments as well as at the TPM boards TPM measures have been defined and tracked Quantities, OEE key performance indicators and changeover times have been measured daily Deviations from standards will be recognisable Employee qualification Problem solving techniques (PLB) BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 7
8 Aufzug A Aufz ug A 3 B 3A Te llen B 3 A Te llen h Quick changeover Changeover procedures have been standardised, changeover times and buffers have been reduced, changeover frequency has been increased and batch sizes have been decreased Front panel production - Changeover time has been reduced from 39 to 16 min - Cycle time reduced as well Final drum production - Changeover time has been reduced from 23 to 17 min Workshops that span multiple factories - Facilities the exchange of specialised knowledge - Furthermore, an exchange with FIW, FCW, FLW, FDW SMED Wegedarstellung Anlage: Trommelfertigung FK Hersteller: Fa. Miramondi/Tellen Datum: m CP 6 5 6m 6m 6m CP SMED Wegedarstellung Anlage: Trommelfertigung FK Hersteller: Fa. Miramondi/Tellen Datum: m 12m CP m CP 12m 8 16m 9 12m m 6m 6m 116m 11 2m CP 1m 35m 7m 5 2m CP 2 16m 1 16m 3 12m 17m BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 8
9 Main assembly line 13 Copy of main assembly line, reduced to max. 7 work stations Production of customized variants and pre-series Employee qualification and job training Production smoothing of assembly line 1 BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 9
10 Increase of factory output capacity Capacity/ 8h shift Project plan TG 86 TG 8 TG 71 TG 67 curr. status Note: +23 units, +38% enhancement of factory output vs. plan BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 1
11 BSH Production System activities 28 Implementation evaluation BSH PS Workshop Stability and sustainability Maintenance week Assembly AU 13 Communication centre Dialogue in Sommerfeld Process stability TPM and SMED Responsibility matrix Standard operating sheet Kick off Teamwork with godfathers Qualification and job training CIP Jan. Feb. Mar. April May June July Aug. Sept. Oct. Nov. Dec. Kick off Best Office Nauen Information market Synchronised assembly line Implementation TG 67 Simulation TG 67 FM Production Evaluation SMED Workshop Qualification concept Workshop Optimisation CIP Start-up AU 13 Synchronised assembly line line stop concept Pilot Increase of factory output capacity 28 Process stability and preventive maintenance (TPM) Dialogue in Sommerfeld Visual management BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 11
12 Das Ziel ist für Ebene der Leistungs - Steigerung Einführung des FNW PS Produktivitätssteigerung 1. Ebene der Leistungs - steigerung BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 12
13 Increase of factory output capacity BSH Production System Demand oriented production Robust product phase-in / phase-out Challenging and fostering our people Avoiding defects (zero defects) Avoiding waste Pull-principle ABC/XYZ-Analysis JIT/JIS Kanban Milk run Supermarket Vendor Managed Inventory Customer takt One-piece-flow Production smoothing and leveling Quick changeover Value stream mapping/ design Procurement management Make or Buy Procurement marketing & supplier selection Supplier integration Supplier management Phase-in / phase-out management Variants management and ECO Production order release Project management Planning guideline Resource and time planning Risk and escalation management Product development process (PEP) see PEP guideline = principle Teamwork Human relations barometer Team briefing Responsibility matrix Employee qualification and development Country specific tools Train- and qualification teamleader and processupporter Performance orientation Country specific tools Defect prevention FMEA Poka Yoke SPC Defect detection / test planning Line stop concept Product audit Testing Worker self check Reliability tests Defect analysis / correction Complete FPY recording Field failure analysis Quality feedback loops Analysis of returns Standardisation and Sustainability = method 6 - SIGMA = tool Standardized work Work place organization (5S) Standard operating sheet Total Productive Maintenance (TPM) Visual management KPI management Labeling and markings CIP Problem solving techniques Improvement workshops BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 13
14 Increase of factory output capacity Capacity/ 8h shift Reduction of TG to 55 until 21 - workplace reinvention - synchronised assembly line incl. line stop concept Project plan TG 67 TG 55 Note: +2 units, +68% enhancement of factory output vs. plan BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 1
15 BSH Production System activities 29 KPI management Work place organization Milk Run Project management Defect detection Poka Yoke Legend: Topic of the year Topic of the month Target Supermarket Six Sigma Jan. Feb. Mar. April May June July Aug. Sept. Oct. Nov. Dec. SMED Synchronised assembly line incl. line stop concept SMED Dialogue in Sommerfeld Avoiding defects SMED 29 Process stability stable flexible TG 55 Dialogue in Sommerfeld BSH PS 21 BSH Hausgerätewerk Nauen GmbH, 28 Festo Didactic_Kolloquium 2. März 29 I Folie: 15
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