Sirona Dental A/S Operations Excellence

Transcription

1 1 Sirona Dental A/S Operations Excellence June 2014

2 2 Et produkt i 2 farver! Internal & external cleaning (ISO Annex J ) Lubrication Sterilzation (EN13060) 6 instruments in 16 minutes Fully automized process Press one button!

3 Den unikke proces sikrer rene og sterile instrumenter 3 INTERNAL CLEANING LUBRICATION EXTERNAL CL EANING STERILIZATION Step 1 Step 2 Leak test Internal cleaning: The internal channels are flushed with water Step 3 Lubrication: The drive channels are lubricated Step 4 Step 5 Step 6 Step 7 External cleaning: The instruments are cleaned with pulse wash Hot wash: Steam at 107 C Heating procedure: To 134 C Back flush: Saturated steam is forced through the instruments Step 8 Sterilization: 3 minutes at 134 C Step 9 Back flush Step 10 Drying Step 11 Lid opens slightly Step 12 Lid opens completely when pressing the C button

4 HISTORIE Nitram Dental A/S founded 2000 Launch of the DAC 2OOO 2002 W&H approves DAC 2OOO 2004 DAC Universal is as launched as a new flagship product DAC Universal approved by Sirona and W&H Nitram Dental A/S becomes part of the Sirona Group 2005 Nitram introduces Sirona branded DAC Universal 2. Generation of DAC Universal with improved oil system 2007 The cleaning process is approved and documented according to the standard ISO Annex J Generation of DAC Universal launched 15,000 DAC Universal autoclaves sold Børsen Gazelle 2011 Børsen Gazelle 2012 Company name changes to Sirona Dental A/S. Sales integrated into the mother company New ERP system implemented in 6 months ,000 DAC Universal autoclaves sold Lean Quality project transforms the company Global Confidence Test proves reliability of the improved DAC Universal 2014 A year of records! Start up Kvalitet Growth Growth Clean up!

5 NYT ERP SYSTREM PROJECT OBJECTIVES 5 Q3 13 Business impact Reduced direct costs Reduced overhead cost Reduced inventories Fewer mistakes and better service Q1 13 October 12 Automation - efficiency Automated order handling Automated reporting Elimination of redundant typing Elimination of sub-systems Processes, System and data Up-to-date ERP system scalable for growth Shop-floor registration Cleaned master data Optimised and documented processes Transparency better decisions Standard reporting for Finance Quality Delivery performance Cost and inventories Supplier performance Sales

6 Quick go live. Refinement later Area Phase 1 Basic functionality October 12 go-live Finance, BI and HR Accounting AMC banking Invoice approval workflow Basic reporting Sales and order handling Order handling, incl ATP Manual booking of transportation Sourcing and Procurement Supplier management Procurement Production Production order scheduling Production execution Shop Floor Control Time registration (Direct on production orders for pre- and main assembly. Indirect for rest) Salary, absence management, injury and illness tracking Phase 2 Harvesting benefits November 12 to March 13 Management Reporting Financial reporting Enhanced version of rolecenters Travel expenses management Integration to OnVentis (Sirona) Automated booking of transportation with Consignor Automated invoicing Out of scope Employee development and competency management CRM Customer complaint (mydoc) Approval workflow Automatic handling of dual sourcing Operational reporting Monthly master planning Capacity planning 6 Inventory and Quality Management Simple reorder points Inbound quality control Traceability of component SNs Service and support Quotation Service Orders / or production orders Master data No automated migration. All data will be validated and typed Repair planning Service agreements / Subscription Customer Service Portal

7 A dedicated team effort, world class consultants, an agile project model and a best ofbreed system has been the combination enabling success 7 The team Tove Nielsen Lis Kristensen Bettina Madsen Berit Rossen John Pallesen Linda Vullum Jens O. Holck Galya Yordanova Claus Bisgaard Management attention Fast decisionmaking process Dedicated team effort Go-live in 6 months World-class consultants from Optimate Best-ofbreed ERP system AX12 An agile project model

8 PROJEKT: LEAN QUALITY 8 I dag Skubbe produktion med mange undersamlinger og stort lager (4,6mDKK svarende til 26 dage) Kvalitet baseret på sortering med en First Pass Yield på 47% Tre hovedprodukter DAC MK2, DAC MK3 og NitraDem Fremtid Produktionslinie med de fleste undersamlinger integreret, hvilket vil reducere lager med 50%+ Kvalitet gennem proces stablitet og deraf stærkt forbedret First Pass Yield Kun to hovedprodukter DAC MK3x og NitramDem LEAN QUALITY

9 PROJEKT PLAN apr maj jun jul aug sep okt nov dec jan feb mar Workshop og etablering af team Fejl analyse Fabriks layout Design Implementation Produktionslinie, incl kvalitetstjek Design/muck-up Implementation Kvalitetsforbedringer Produkt og proces Test koncept Concept development Slut test Development and test Replace test-room Leverandør Supply Chain planning Analysis Implementation Milestone 1 Milestone 2 Milestone 3 Milestone 4

10 Lean Quality: Status and next steps 10 Completed actions New site layout New one piece flow assembly line for DAC Universal Insourced sub assembly for Valveblock New Supermarket inventory concept Process oriented flow for test Improved inbound control process Improved products with 84 updates (ECO) Restructured organisation Implemented systematic kaizen processes and leadership -83% % 1 Sub assemblies Count % % WIP value tdkr 356 May 2013 Today Target Test -81% Assembly -65% Required actions to realise targets Lead time Minutes New test concept (FY saving 107tEUR) New heating element design and supplier Insource hose pre production (FY saving ~50tEUR) New lean production line for Nitradem Finalise spareparts lean concept Drive Continuous Improvement % +51% +27% % Productivity Minutes per DAC First Pass Yield %

11 11 OLD BATCH PRODUCTION (Step 1 3 only) Pre assembly 7,8 min 40pcs 15,6min 20pcs 0,06min 200pcs 7,8min 30pcs 7,8min 50pcs 7,8min 10pcs 7,8min 50pcs 7,8 min 200pcs 7,8min 30pcs 86,2min 80pcs 31,2min 110pcs WIP inventory 8tkr 19 89tkr 106 1tkr tkr 122 9tkr 69 97tkr 81 11tkr 36 6tkr 28 33tkr tkr tkr 116 Final assembly Total WIP value 511tkr Longest lead time min 20 min (57,6 min) 1pcs Total work time per DAC: 207,66 min

12 12 NEW FLOW PRODUCTION (Target step 1 3) Flow min 20 min 20 min Step 1 Buffer Step 2 Buffer Step 3 Total WIP value 15tkr Longest lead time 100 min Total work time per DAC: 125 min

13 The process of creating the new DAC assembly line 13 June 2013 February 2014 May WS to create the production line 1 WS to create inventory supermarket 1 WS to insource valveblock sub assembly 1 WS to create new spareparts process 1 WS on test flow Practise re balancing Continuous Improvement Review perform. Mapping of current process Produce on muck-up Team effort World class coaching from ManEx Leadership Improve process Build muck-up

14 First two muck up workstations in operation with one piece flow 14 Station 1 Station 2

15 New production layout 15 Walkway DAC producon line Available space Valve battery insourcing Test area Work test Packaging Goods in Goods out DAC preparaon/cleaning

16 Functional test is improved, while works validation test is unchanged 16 Today Endurance test against failure Supplier Component Component Inbound control Module test Test 1 1 cycle Testroom 40 cycles Self test Test 2 1 cycle Finished DAC Testroom 40 cycles Self test Test 3 1 cycle Validation test EN cycles with external sensors Future Variation test against standard Supplier Component Functional test of components and assembly. Relevant to avoid system break down, but not to validate sterialisation process Component Inbound control Module test Finished DAC Factory Acceptance Test (FAT) Integrated one plug Functional Performance Test Works test Validation of sterialisation process Validation test EN cycles with external sensors

17 Bagklogskabens klare lys 17 Lyt til kunderne ikke til ingeniørene Produktion før administration Lean først > layout og domicil bagefter Husk at der er 6 til 12 måneders forsinkelse i kommunikationen til moderselskabet Kultur klar til forandring: Kontrol cirklen, grøn bane og værdi loyalitet Husk at Projekt risiko kan mitigeres med erfarne folk