iiea 14july 2021 - francis hiew
TRANSCRIPT
Francis Hiew
IIEA14 July 2021
Experience Sharing Session onOperational Excellence in Aerospace Manufacturing Industry
MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN
MRO
FH - Introduction
1997-1999
Pacific Aviation Composites LLCBend, Oregon, USAAVP – Operations
Lancair Columbia 300
• 4-Seater all composites GA – F
• Design, development, certification and production
1999-2008
Composites Technology Research Malaysia Sdn. Bhd, Malaysia (CTRM)General Manager , COO
• Advance Composites Aero-Structures Mfg for Airbus & Boeing
• Aviation- Eagle Aircraft 150B• Aerospace Design Center • UAV & Systems Integration
(Defense)• Advance Composites –
Automotive, Marine
2008 -2016
Spirit AeroSystems Malaysia Managing Director
• Aero-Structure Assembly• Aero-Structure Design• A320, A350, 737,787• Regional Supply Chain
Development
• Malaysia Aerospace Industry Association –Deputy President (2016-2017) MAIA
2017 - Present
Francis Hiew Consulting (Malaysia)
• Spirit AeroSystems Malaysia –Director (2018), Consultant (2019)
• MAIA – Advisor• Aerospace tooling capability
development• Training & Advisory
• Strategy • Leadership• Skill and Capability• Lean & Continuous
improvement
MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN
MRO
Spirit AeroSystems Malaysia Sdn Bhd
• Established in 2008, Subang Airport. Selangor Malaysia• Wholly owned subsidiary of Spirit AeroSystems Inc, Wichita, USA. • Core Capabilities –
• Metallic and Composites Aero-Structure Assembly• Product Design• Supply chain development and management
Products:A320 – Flap Track Fairing, Spoilers, Over-wing Panels, etc.A350 – Root End Fixed Fairing , Leading Edge Panel Assembly787 – Fixed Leading Edge737 – Doors, Fuselage sub-assemblies,
MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN
MRO
Spirit AeroSystems Malaysia Sdn Bhd
Version 2SPIRIT PROPRIETARY
Spirit Malaysia Roadmaps
Spirit Malaysia Roadmaps
LEAN Roadmap
Operations Roadmap
Growth Roadmap
Supply Chain Roadmap
Talent Management Roadmap
Technical Roadmap
Recognition/Certification Roadmap
Preferred Future State
(Operational Excellence)
• Reduction in Total Unit Cost.• Improved Product Cycle Time.• Reduction in Cost of Product Quality• Improved Inventory Management
The existing Spirit Malaysia roadmaps are steering the organization towards Operational Excellence
4Spirit MalaysiaProprietary Information - Spirit AeroSystems Malaysia Sdn Bhd
AIMS 2009AIMS 2010AIMS 2011AIMS 2012AIMS 2013AIMS 2014AIMS 2015
Vision
Mission
5 Year Preferred Future State
Tech
nica
l R
oadm
ap
Lean
R
oadm
ap
Supp
ly C
hain
R
oadm
ap
Tale
nt
Man
agem
ent
Roa
dmap
Gro
wth
R
oadm
ap
Rec
ogni
tion/
C
ertif
icat
ion
Roa
dmap
Core Values
Getting there ...
Version 2SPIRIT PROPRIETARY
Journey Towards Operational Excellence through a Sustainable Review Process
RESOURCES CAPABILITIESKNOWLEDGE
Setting of goals / targets
Defining the current status of the
various sites (Gap Analysis)
Defining strategies / roadmaps
Developing a sustainable review process to manage
performance
Milestones and targets assessment/alignment conducted on an annualbasis (Head of Sites)
• Operational Excellence Conference conducted on a quarterly /half-yearly basis to report progress on CI activities• Annual site assessment for LEAN / CI
Strategies / Roadmaps to be reviewed on an annualbasis to align short term milestones to goals/target
Formal Monthly Review/Tracking on CI activities at various sites through Internal Management Meetings and Contract Reviews
Vision Rolling 5-YearRoadmap
Annual BudgetAction PlanCompany –KPIPerformance Bonus
Department - KPIs & BudgetWork Center - KPIs & BudgetKPIs Tracking
Daily-Weekly – Monthly- Quarterly
Employees of all levels and all departments share and own the company’s Vision, Strategies, Action Plans and Budget
MRO
Operational Excellence Journey Composites Technology Research MalaysiaSpirit AeroSystems Malaysia
Constraint Management
5S + Safety
Process ControlVisual Management System
Defects Prevention-Poka-Yoke-Hot Spot Visual Training
Self Manage Team
Kaizen – Continuous Improvement
Standard works
Skill & Product Training
Product Training Manual
One Piece Flow
Andon Light – Call for Action
Strategically placed inventory
Lean Awareness Training
Root Cause Corrective Action
Lean Roadmap
Value Stream Mapping
Visual Learning –Good part / Bad part
Operational Excellence Roadmap
Autoclave – SMED process
KPI Pyramid
Line BalancingLesson Learnt
Lean Maturity
Smart Tooling (Jigs & Fixtures)
Focus Improvement – Rapid Improvement Workshop
Waste elimination
TPM
Business Continuity Plan
MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN
MRO
Spirit AeroSystems Malaysia Sdn Bhd – Innovations and Achievements
Roadmap = Action Pan = Budget• ICE – Slush – Water• 18 months – 3 Year – 5 Year18 Months – ICE = Budget 3-Year = Slush 5-year = Water
- Pledge to change - Change Leadership- Change agent
training- Lean – 5S training- Set KPI- Data collection
system- Strengthen current
customers base- Path to earn the right
to grow
- Set technology path
- Build and protect business differentiators
- Self Managed Teams
- Target for new customers
- Target for new industries
- Ready for growth
- Set Path as market leader in??
- Brand recognition- Industry 4.0 ready
Jigs & Fixtures- Best value J&F in
the region- Ready for export
to USA & Europe
Regional Tooling Capability Development- Started 2016- All Assembly J&F sourced locally in
the region by 2019- Smart Tooling – IR4.0 ready
2Spirit Proprietary
Lean Road Map
Implementation
Monitoring
ReviewsLean Maturity Assessment
Overview of Continuous Improvement Program
• TRAINING & AWARENESS• EXECUTION
ü Monthly 5S competitionü Improvement and Focus
projects registration
VALIDATIONü Financial numberü Effectiveness ü Sustainability Customers comments:
✓Best in Class✓Benchmark for Operational Excellence✓Excellence training and capability development program
Developed Regional Supply Chain• Capability Insertion• Certification• Strengthen Regional Supply Chain
Eco System
MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN
MRO
Turning Vision and Strategy Into Reality
Operational Excellence RoadmapLean RoadmapTalent Management RoadmapSupply Chain RoadmapGrowth RoadmapTechnology RoadmapRecognition & Certification Roadmap
Turning Vision and Strategy into Reality