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QRM Journey Quick Response

Manufacturing @ Hansen

5 -11- 2013 Eric Goos

W E L C O M E

HANSEN INDUSTRIAL GEARBOXES

Driven by gear technology, Hansen Industrial Transmissions fulfils the needs of its global

customer base by offering them reliable mechanical power transmission solutions for

demanding industrial applications.

INDUSTRY APPLICATIONS APPLICATIONS AND CUSTOMERS

ORGANISATION

¬ Edegem Belgium

HIT – Industrial Gearbox Factory

Employees: +300 Surface: Total: 50,000 m² - Factory: 30,000 m² Functions: R & D, Engineering, Production, Assembly, Sales & Service , Finance , HR Quality assurance: ISO 9001 - since 02.01.1991

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What is QRM? Quick Response ¬ Think different about LT: Highlight the power of time Create the right Organisational structure Understand the system dynamics Apply it to the whole organisation

Total lead time: 30 days

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Who is Rajan Suri? An inspiration

Meet the expert

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Functioneel Cellulair

Top down Control

Team Ownership

Specialisten Cross trained

Efficiëntie Tijdreductie

1. Organisatie

2. Management

3. Personeel

4. Mindset

Traditioneel QRM

The Organisation structure changes…

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How did we start? ¬ Get training in to QRM:Spread the word & get Guidance ¬ In early beginning send several people to masterclasses ¬ appoint someone to coordinate the QRM journey. ¬ Today about 180 people have had personal training ¬ Read and understand your company. ¬ Try out some (new) things / do a pilot / experiment ¬ Build a plan and be willing to adjust if needed.

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Investigate the whole process?

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Define a FTMS and try it out.

¬ 3 december 2012 we started a pilot in the CT -> Q-ROC CT ¬ Ending Januari 2013 this was evaluated and LT in order

handing was between 25% to 50% with only two people. ¬ Building the new organisation started around self steering

teams with following focus: ¬ Bringing people from Sales, Engineering &

Workpreparation together in one team. ¬ Talk and communicatie to eachother, organize yourself /

shorten com. channels ¬ Change management

FTMS = FOCUS TARGET MARKET SEGMENT

Q-ROC = QUICK RESPONCE OFFICE CELLS

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ACE PROCESSEN

MCT visibility ORI008748QVRD2-CUN-11.2 ORI008748QVRD2-CUN-11.2 ORI008748QVRD2-CUN-11.2 ORI008748QVRD2-CUN-11.2

U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12 U60-NJ228EQ 1 132.12

ORI008675E17-V230B004ORI008822E17-V230B004ORI008822E17-V230B004ORI009055C17-V230B002ORI009055C17-V230B002ORI008357E17-V230B507ORI008357E17-V230B507ORI008866E17-V230B004ORI008822E17-V230B004ORI008357E17-V230B507ORI008524C17-V230B002ORI008524C17-V230B002ORI008845E17-V230B004ORI008524C17-V230B002ORI008524C17-V230B002ORI008819E17-V230B575ORI008819E17-V230B575ORI008524C17-V230B002ORI008524C17-V230B002ORI008524C17-V230B002ORI008524C17-V230B002

JE17-V203B001 JE17-V203B001 JE17-V203B001 JC17-V203B001 JC17-V202B001 JE17-V203B001 JE17-V203B001 JE17-V203B001 JE17-V203B001 JE17-V203B001 JC17-V202B001 JC17-V203B001 JE17-V203B001 JC17-V202B001 JC17-V203B001 JE17-V203B001 JE17-V203B001 JC17-V202B001 JC17-V203B001 JC17-V203B001 JC17-V202B001

Manufacturing Critical Path Time

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ACE PROCESSEN

Q-ROC teams order gerelateerd… FTMS = Focus Target Market Segment - Offertes & Orders , claims - Per applicatie? Per Regio? Per categorie? Of een combinatie?

Per Regio, en met focus op categorieën ABC => “Fast track”

Team 1: DACH – RU – IN – SCA

Team 2: BNL – JP – UK - ME (eng)

Team 3: LAT – IT – SCAN (LAT = Latijns EU: Fr/Sp/P)

Team 4: CT (koeltorens)

Team 5: GROUP

Vertical Design Team

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ACE PROCESSEN Q-ROC teams order gerelateerd… Team 1: DACH – RU – IN – SCA

Team 2: BNL – JP – UK - ME (eng) Team 3: LAT – IT – SCAN

Team 4: CT

Team 5: GROUP

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ACE PROCESSEN

TEAM Targets & KPI’s

-Focus on Leadtime (LT) reduction (-50%) for a better OTD.

-Focus ON .. First time right (FTR)

-Focus on Crosstraining en Knowledge sharing (cross departmental)

Introduction of QRM number in every team QRM Number = Baseline measurement X 100 Current measurement

ORDERRELATED teams

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ACE PROCESSEN

Orderrelated Q-ROC teams

consolidated results

CAT A

CAT A

CAT B

CAT B

Overview YTD

CAT A

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ACE PROCESSEN

QRM journey today and next steps

Planning: projecten + trainingen najaar 2013.

1. Projecten

Naam OnderwerpAfgevaardigdeQROC - CT

AfgevaardigdeQROC - BNL

AfgevaardigdeQROC - DACH

AfgevaardigdeQROC - LAT

AfgevaardigdeQROC - Group

AfgevaardigdeQROC - DEV

deelnemersQROC - Group

deelnemers QROC-

SPARES

deelnemers QROC-

REPAIRS

deelnemers QROC-ONSITE

deelnemers QROC-

DEVELOPMENT SERVICES

1 Customer intimacy

Standardisatie van een geselecteerde klant binnen uw team.

Dit zowel op het vlak van offerte als orderverwerking

EDC

2 Workflow document

Finaliseren en integreren van het workflow document.

Dit is een nieuwe manier van werken over het hele bedrijf

en zal gedeeltelijk de PCF vervangen.

DNI (MSC) VDRHK (backup)

DVH WVD (SD) VMA DV SSM (VOK)

3 HPP support

Trachten om de behandeling van HPP dossiers te

vereenvoudigen en indien mogelijk zoveel als mogelijk te automatiseren.

KRO (LDE)HK

KPE (backup) LM WVD (GIK) JVG SCD SSM IAD PCA

4 Long LT BOM

Trachten om de werkvoorbereiding (status 2R) eenvoudiger

te maken en een aantal zaken indien mogelijk te automatiseren.

DNI (KRO) HKELR (backup)

PAD WVD (CM) EDC/DV

5 MaattekeningenStandardisatie en regels ivm 97

tekeningen + eventuele vereenvoudigingen.

KRO (LDE)KPE

SVE (backup) LM JVR (CM) NA

6 FTR - 1300 lijn

Afspraken maken ivm behandelen en ingeven AR's.

Vebeteringsacties definiëren om FTR omhoog te brengen.

LDE (KRO) SVEKPE (backup)

PAD JVR (WVD) WMA DMT

7 FTR - checklistHoe gaan we om met nazicht en

zelfcontrole om onze FTR omhoog te brengen.

MSC (DNI)ELR

BR (backup) WL CM (GIK) DMT GAL/SSM GJ MDI

8 Process + procedures

Hoe borgen we alle gemaakte afspraken op

een gestructureerde manier en hoe zorgen we dat weetjes universeel ter

beschkking worden gesteld.

MSC (LDE)ELR

VDR (backup) LOB GIK (CM) NA VOK GJ CAS

9 Resource planning

Een beeld creeëren van de workload binnen de teams om steeds het

overzicht te kunnen houden en soms prioriteiten te bepalen.

DNI (MSC)KPE

VDR (backup) VES WVD (CM) NA DMT SSM/VOK

Heel het teamBR(BNL) - WL(DACH) - LDE(CT) - GIK(LIS) - NA(AC)

¬ Crosstraining from the teams / over the teams ¬ Time slicing with several other departments ¬ Top 9 most urgent trainings with eye on flexibility ¬ Not only office but also Shop floor

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THANK YOU

Questions?