value adding activities - lean concepts
DESCRIPTION
Visual Management based in real time data from production and quality control, using lean approach and supplier developmentTRANSCRIPT
Carlos E. DaSilva (978)442 [email protected]
0110 Worcester Section
January Meeting - 2004
Lean Concepts to Meet:Value-adding Activities
By Carlos Eduardo DaSilva
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
Tyco Electronics is the world-leading supplier of passive electro-mechanical components. The high-tech products of its brands like AMP, ASG, EC, Elcon, Elo TouchSystems, HTM, M/A COMM/A COM, Madison Cable, Netconnect, Raychem, SIMEL, Schrack, OEG and P&B have been used in various applications of the following sections:
• Automotive • Communications-Equipment• Computer and Consumer Electronics• Industrial and Commercial• Energy• Modules and Relays• Wireless Products
• Telecom and Outside Plant• Premises Wiring• Connectors/Interconnection Systems• Application Tooling• Energy• Printed Circuit Boards• Wire and Cable Products
TYCO ELECTRONICS IN PROFILETYCO ELECTRONICS IN PROFILETYCO ELECTRONICS IN PROFILETYCO ELECTRONICS IN PROFILE
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
DISTRONIC ADAPTIVE CRUISE CONTROLDISTRONIC ADAPTIVE CRUISE CONTROLACC Lab – Lowell , MAACC Lab – Lowell , MA
Tyco International
Tyco Electronics
M/A COMwww.macom.com
Microwave Solutions Business Unit
Automotive Sensors and Telematics Group
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
S-Class Mercedes
DC Actros Truck
CL Mercedes
E-Class Mercedes
Nissan Cima
Cadillac DeVille
Coming 2004
THE CUSTOMERSTHE CUSTOMERSTHE CUSTOMERSTHE CUSTOMERS
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
Dimensions (mm) Width: 137.6Length: 146.9Height: 57.9
ACC 77 GHz Sensor
Frequency 76 to 77 GHz
Technology Pulsed Doppler
MMIC based design
Output Power 58 to 66 dBm EIRP*G/F
Antenna 3 beams separated by 3.5°
Electronic beam switching
Beam Width 3 degree (-6 dB)
Sidelobes -30 dB Min
Freq Switching < 5 nS
THE PRODUCTTHE PRODUCTTHE PRODUCTTHE PRODUCT
Carlos E. DaSilva (978)442 [email protected]
Data transformed becomes information.Data transformed becomes information.
Information transformed becomes intelligence.Information transformed becomes intelligence.
Intelligence transformed becomes competitive advantageIntelligence transformed becomes competitive advantage ..
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
QUALITY AS RESULT OF HUMAN EXCELLENCEQUALITY AS RESULT OF HUMAN EXCELLENCEQUALITY AS RESULT OF HUMAN EXCELLENCEQUALITY AS RESULT OF HUMAN EXCELLENCE
HOW TO MAKE THE CHANGEHOW TO MAKE THE CHANGEHOW TO MAKE THE CHANGEHOW TO MAKE THE CHANGE
Carlos E. DaSilva (978)442 [email protected]
GROUP BEHAVIOR / ORGANIZACIONALTEAM BEHAVIOR
Management
INDIVIDUAL BEHAVIOR SKILLSINDIVIDUAL BEHAVIOR SKILLSACTION
INDIVIDUAL BEHAVIOR SKILLSINDIVIDUAL BEHAVIOR SKILLSACTION
ATTITUDE COMPETENCEATTITUDE COMPETENCE
Assurance
ATTITUDE COMPETENCEATTITUDE COMPETENCE
Assurance
KNOWLEDGEKNOWLEDGEKNOWLEDGEKNOWLEDGE
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
TRANSITION CYCLETRANSITION CYCLETRANSITION CYCLETRANSITION CYCLE
Carlos E. DaSilva (978)442 [email protected]
Tools: Balanced Scorecard; 6Sigma; Corrective/Preventive Actions Notification; Audits (System/Process/Product) ; Recognition Program; etc.
IPIKNOWLEDGE SYSTEM
Project A 2002 Project B 2003 Project C 2005
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE PLANTHE PLANTHE PLANTHE PLAN
Carlos E. DaSilva (978)442 [email protected]
PEOPLEPEOPLE
PROCESS
PROCESS
PROCESS
PROCESS CO
NTR
OL
CON
TRO
L
CON
TRO
L
CON
TRO
L
PEOPLEPEOPLE
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE ACTIONTHE ACTIONTHE ACTIONTHE ACTION
Carlos E. DaSilva (978)442 [email protected]
KEY LEAN CONCEPTSKEY LEAN CONCEPTSKEY LEAN CONCEPTSKEY LEAN CONCEPTS Plant Level
“It transfers the maximum number of tasks and responsibilities
to those workers actually adding value to the car on the line, and it has
in place a system for detecting defects that quickly traces every problem, …”
“It transfers the maximum number of tasks and responsibilities
to those workers actually adding value to the car on the line, and it has
in place a system for detecting defects that quickly traces every problem, …”
THE MACHINE THAT CHANGED THE WORLDJames P. Womack, Daniel T. Jones, and Daniel Roos
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
TP
S
THE BENCHMARKTHE BENCHMARKTHE BENCHMARKTHE BENCHMARK
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
“Thinking”Production
System
= ToyotaT
THE BENCHMARKTHE BENCHMARKTHE BENCHMARKTHE BENCHMARK
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
PROCESS(Set of interrelated or interacting activities –
must be inspected and controlled)
INPUT OUTPUT
(Includes Resources)
PRODUCT(Result of a process – Must be Audit)
MONITORING AND MEASUREMENT OPPORTUNITIES FOR IMPROVEMENT
Before, during and after the process
THE ISO APPROACHEDTHE ISO APPROACHEDTHE ISO APPROACHEDTHE ISO APPROACHED
Carlos E. DaSilva (978)442 [email protected]
IPIKNOWLEDGE SYSTEM
Tools: Balanced Scorecard; 6Sigma; Corrective/Preventive Actions Notification; Audits (System/Process/Product) ; Recognition Program; etc.
Project A Project B Project C2002 2003 2005
Database
Reports
MRB
Metrics
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE PLANTHE PLANTHE PLANTHE PLAN
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE RESULTTHE RESULTTHE RESULTTHE RESULT
• REAL TIME INFORMATION• REAL TIME KNOWLEDGE• REAL TIME DEFECT IDENTIFICATION• REAL TIME CICLE TIME• REAL TIME COST OF POOR QUALITY• REAL TIME PROCESS VARIABLE STUDY• REAL TIME TEAM WORK
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
WASG Pareto of Defects - Twist Plate Assembly
1000009164-0001
12
6
4 4
2 2 2 2
1 1 1 1 1 1 1 1 1 1
0
2
4
6
8
10
12
14
TUN
E: N
EE
DS
EX
CE
SS
IVE
TUN
ING
TES
T FAIL: D
EFE
CT
UN
KN
OW
N
RIB
BO
N B
ON
D: LIFTE
D /
BR
OK
EN
HA
RD
WA
RE
: OTH
ER
SW
ITCH
CH
IP: LIFTE
DB
ON
D PA
D
RIB
BO
N B
ON
D: M
ISS
ING
WIR
E B
ON
D: LIFTE
D /
BR
OK
EN
PC
B: O
THE
R
MIX
ER
DIO
DE
:E
LEC
TRIC
AL FA
ILUR
E
TWIS
T CIR
CU
IT: OTH
ER
MM
W C
IRC
UIT: D
AM
AG
ED
TES
T: RF P
ULS
E FA
ILUR
E
TUN
E: O
THE
R FA
ILUR
E
SW
ITCH
CH
IP: O
THE
R
SW
ITCH
CH
IP: D
AM
AG
ED
RE
S C
IRC
UIT: D
AM
AG
ED
MM
W C
IRC
UIT: O
THE
R
EX
CE
SS
EP
OX
Y: MM
IC
MSBU
Created 10/1/2002 1:05:01 AM
THE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENT
Carlos E. DaSilva (978)442 [email protected]
AUTOMOTIVE SENSORS PRODUCT LINE Weekly First Pass Yield for ACC LAB ( 1000009164-0001 )
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
13 '02 14 '02 15 '02 16 '02 17 '02 18 '02 19 '02 20 '02 21 '02 22 '02 23 '02 24 '02 25 '02 26 '02 28 '02 29 '02
Weeks
FPY 2nd Pass WIP Scrapped
MSBU
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENT
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENTTHE MANAGEMENT
IPI MANAGEMENT REVIEW LEVEL
Quality Assurance
IPI ENGINEERING REVIEW LEVEL
Quality Control
IPI – OPERATOR LEVEL
Quality Management
Effectiveness Efficiency
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
When we talk about defects in our factories, we are talking about defective processes. If there’s a defective process, it’s going to
turn out defective products.However hard you examine a defective product,
it doesn’t improve the process. So we should focus on defective processes.
Components move from supplier to supplier in a flow,and unless an excellent control system is in place, it’s impossible to prevent defects from occurring.
Teruyuki Minoura, Former President,Toyota Motor Manufacturing, North America
Carlos E. DaSilva (978)442 [email protected]
IPIKNOWLEDGE SYSTEM
COMAKERSHIPSUPPLIER MANAGEMENT
Tools: Balanced Scorecard; 6Sigma; Corrective/Preventive Actions Notification; Audits (System/Process/Product) ; Recognition Program; etc.
Project A Project B Project C2002 2003 2005
Database
Reports
MRB
Metrics
Database
Reports
SCAR
Metrics
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE PLANTHE PLANTHE PLANTHE PLAN
Carlos E. DaSilva (978)442 [email protected]
WHAT IS CO-MAKERSHIP ?WHAT IS CO-MAKERSHIP ?
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
Its the establishment of a relationship management between Customer and Supplier to achieve the extremely value add and the total customer satisfaction, through: Quality AgreementQuality Agreement
Lean Supply ChainLean Supply Chain Just in TimeJust in Time
Carlos E. DaSilva (978)442 [email protected]
Completed
In process
Supplier Guide
Draft Version
Quality Agreement
Draft Version
Supplier Guide
Draft Version
Supplier Guide
Draft Version
Quality Agreement
Draft Version
Supplier Database
Draft Version
Supplier Relationship
Process
Supplier Agreement
Meeting
Review draft SRG and QAA ;Review draft SRG and QAA ;Meeting with Sensors Product Line Team;Meeting with Sensors Product Line Team;Meeting with Supplier Quality Manager;Meeting with Supplier Quality Manager;Release SRG and QAARelease SRG and QAA
CRITICAL & VITAL CRITICAL & VITAL
Implement Supplier
Relationship Management
Week 27 29 33 36 40 45 48
Time Line FY’ 03
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE SUPPLIER RELATIONSHIPTHE SUPPLIER RELATIONSHIPTHE SUPPLIER RELATIONSHIPTHE SUPPLIER RELATIONSHIP
Carlos E. DaSilva (978)442 [email protected]
Supplier Relationship GuideSupplier Relationship Guide
All suppliers of Automotive Sensors Product Line
Based on ISO 9001:2000 and ISO/TS 16949:2002 with references toVDA 6.1 and QS 9000:1998
Note: M/A COM internal procedures
Supplier Relationship GuideSupplier Relationship Guide
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE GUIDETHE GUIDETHE GUIDETHE GUIDE
Carlos E. DaSilva (978)442 [email protected]
QAAQAAQQuality uality AAssurance ssurance
AAgreementgreementSelected suppliers
Follow the needs of Automotive Sensors Product Line
Technical Agreement with focus on Product Realization and Process Control
Request FMEA, Control Plan, and Corrective Action (8D)
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE AGREEMENTTHE AGREEMENTTHE AGREEMENTTHE AGREEMENT
Carlos E. DaSilva (978)442 [email protected]
IPIKNOWLEDGE SYSTEM
COMAKERSHIPSUPPLIER MANAGEMENT
VISUAL VISUAL FACTORYFACTORY
Tools: Balanced Scorecard; 6Sigma; Corrective/Preventive Actions Notification; Audits (System/Process/Product) ; Recognition Program; etc.
Project A Project B Project C2002 2003 2005
Database
Reports
MRB
Metrics
Database
Reports
SCAR
Metrics
Housekeeping
Visual Aid
KanBan
Integration Center
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE PLANTHE PLANTHE PLANTHE PLAN
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
THE FIVE THE FIVE COMMONCOMMON SSENSEENSETHE FIVE THE FIVE COMMONCOMMON SSENSEENSEThe Principle is: Clean it up, Make it Visual
1.1. SSort – Sort through items and keep only what is needed while disposing of what is not
2.2. SStraighten (orderliness) – “A place for everything and everything in its place”
3.3. SShine (cleanliness) – The cleaning process often acts as form of inspection that esposes abnormal and pre-failure conditions that could hurt quality or cause machine failure
4.4. SStandardize (create rules) – Develop systems and procedures to maintain and monitor the first three SS’s
5.5. SSustain (self-discipline) – Maintaining a stabilized workplace is an ongoing process of continuous improvement
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
VISUAL AID & CONTROLVISUAL AID & CONTROLVISUAL AID & CONTROLVISUAL AID & CONTROLThe Principle is: Can our manager/director walk through the shop floor or office, and recognize if standard work or procedures are being followed?
Carlos E. DaSilva (978)442 [email protected]
DON’T PUSH, JUST PULLDON’T PUSH, JUST PULLDON’T PUSH, JUST PULLDON’T PUSH, JUST PULLSMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
The Principle is: From the inspiration of supermarket - Instead of using a system of estimated replenishment, the store restocks only what has been sold, thereby reducing defective inventories.
The KanBan System is the most critical to implement a TPS model.
The more inventory a company has,…the less likely they will have what they need.The more inventory a company has,…the less likely they will have what they need.Taiichi Ohno
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
DEVELOPING PEOPLE AND PARTNERSDEVELOPING PEOPLE AND PARTNERSDEVELOPING PEOPLE AND PARTNERSDEVELOPING PEOPLE AND PARTNERS
Floor
Automotive Group
Supplier
CUSTOMER
FOCUS
Carlos E. DaSilva (978)442 [email protected]
SMART CAR. SMART CAR. SMART PEOPLESMART PEOPLE.. SMART COMPANY. SMART COMPANY.
SUMMARYSUMMARYSUMMARYSUMMARY
“ This is the result of manufacturing science transitions that we have been working on for at least five years”
Bill Guggina – Operations ManagerDelphi Delco Electronics Systems
Kokomo-IN-USA