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Lean in Henkel Adhesives, EuropeVladimir Martinenko, Manager Lean Enterprise Europe CEE South &
Central Asia and Caucasus
1. Kaizen Congress in SerbiaBelgrade, 28th of Sept. 2017
222
Agenda
1. Did you know about Henkel…
October 2, 2017
2. How Continuous Improvement programs work in Henkel...
3. What does it mean to be Regional Lean manager...
333
… that Henkel is the world's number one adhesives producer?… that Henkel sells detergents for around
25 billion wash loads per year?… that every second, more than 20 hair colorants from Henkel are sold worldwide?
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
Did you know…
444
Who we areLeading positions in consumer and industrial businesses
Adhesive Technologies Beauty Care Laundry & Home Care
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
555
Who we areHenkel at a glance 2016
October 2, 2017
1 Adjusted for one‐time charges/gains and restructuring charges.
More than 50,000employees from 123 nations
42% of our sales generated in emerging markets
More than 140 yearsof success
€3.2 bn adjusted1 operating profit (EBIT)
171 manufacturing and 22 major R&D sites around
the world
Around €18.7 bn sales, +3.1% organic sales growth
1. Kaizen Congress in Serbia, Belgrade
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• Our sustainability strategy: Achieving more with less
• Ambitious long-term goal for 2030:Triple value in relation to our footprint (Factor 3)
• Interim target 2010 – 2020: Increase our overall efficiency by 75%
• External recognition: Leading positions in various national and international sustainability ratings and indices.
What guides usLeadership in sustainability
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
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Status of our sustainability targetsOur progress toward our long-term goal “Factor 3”
October 2, 2017
1 Compared to the base year 2010.2 Waste footprint of our production sites, excluding construction and demolition waste..
1. Kaizen Congress in Serbia, Belgrade
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Henkel Plant in InđijaHenkel Plant in Inđija
Henkel Srbija
Administrative centre in BelgradeAdministrative centre in BelgradeHenkel plant in KruševacHenkel plant in Kruševac
2002. 2008. 2007.
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
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Key Developments
October 2, 2017
1924Name changed to “Merima”, largest soap producer in Balkan region
1924Name changed to “Merima”, largest soap producer in Balkan region
1839Founded as soap & candles factory
1839Founded as soap & candles factory
1961Powder detergents production established
1961Powder detergents production established
1927Cosmetic production started
1927Cosmetic production started
2002Bought by Henkel; new name: “Henkel Merima”
2002Bought by Henkel; new name: “Henkel Merima”
1970First cooperation with Henkel
1970First cooperation with Henkel
2007Adhesive production moved to Indjija
2007Adhesive production moved to Indjija
2004Production of building adhesives started
2004Production of building adhesives started
2011Name changed to Henkel Srbija
2011Name changed to Henkel Srbija
1. Kaizen Congress in Serbia, Belgrade
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Henkel SrbijaIzvozi na 35 tržišta
•Albanija•Austrija•Bosna i Hercegovina•Bugarska•Hrvatska•Mađarska•Makedonija•Nemačka•Crna Gora•Poljska•Rumunija•Turska•Ukrajina•I druga
55 miliona potrošača
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
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Agenda
1. Did you know …
October 2, 2017
2. How Continuous Improvement programs work in Henkel...
3. What does it mean to be Regional Lean manager...
1. Kaizen Congress in Serbia, Belgrade
121212
Development of Lean Manufacturingfrom the KAIZEN- era at Toyota to HENKEL today
HPSHenkel Production System
1950 1980 1991 1992 since1998
2007-2008
2006since1997
20132003
KAIZENera starts at Toyota
2014
KAIZEN translated intoEnglish
Recognition of productivity differences ofup to 40% betweenJapan and Europe/USA
Start of KAIZEN in the Western world
Confirmationof the success factors and methods in various industries
Different Kaizen activities Louviers Düsseldorf Winsford
Introductionof “Site Excellence”
Introductionof “TOPP”inHeidelberg
Roll out of“g4e”DüsseldorfDublinHannover
Roll out of“g4e”MontornésSchönbachCaleppioCasarileCeranoScheemda
Integration of SixSigma in „g4e“
2009-2011
Global Alignment of Continuous Improvement Initiatives & StandardsinAdhesives Operations (AO)
Introduction „Lean Enterprise“inAO Global
future
Alignment of A&B&L
Trans-formationto Henkel Production system „HPS“
Since 1998 Henkel
successfully implements
Lean principles
October 2, 2017 1. Kaizen Congress in Serbia, Belgrade
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Today
Henkel Production SystemAligning A, B, and L Across Henkel
Future
HPSHenkel Production SystemCreate a standard operating system for the Henkel Supply Chain and Operations based on Lean principles that will accelerate performance improvements and create customer value
L
A
Lean Enterprise
B
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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Standards
• Standardized work
• Visual management
• 5S
• Risk based project selection
• Value stream mapping
• CI workshops
• Problem solving
• Quick changeover
• Autonomous maintenance
Henkel Production SystemStandards
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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Standards
• Control Plan
• Error Proofing
• Management of Change
• Statistical Controls
• FMEA
• OEE
• Six Sigma
• Pull System
Henkel Production SystemStandards – Additional in Adhesive Technologies
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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Who we areAdhesive Technologies
€8,961 msales
+2.8%organic sales growth
€1,629 m adjusted1 operating profit (EBIT)
30%innovation rate2
>80%of our sales generated with our top 10 brands
1 Adjusted for one‐time charges/gains and restructuring charges.2 Percentage share of sales generated with new products launched onto the market within the last five years.
1. Kaizen Congress in Serbia, Belgrade
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PortaWestfalica
Hannover
Tallaght
Ballyfermont
Winsford
WesterloAntwerpen
Montornes
Schönbach
Heidenau
Düsseldorf
Bopfingen
Scheemda
Villefranche
Unna
Erlinsbach
Casarile Caleppiodi Settala
Zingonia
NorrkopingPärnu Tartu
Valkeakoski
Zaslavl
Staporkow
DzierzoniowHeidelberg
Környe Oleshky
Vysgorod
Balakleya
CampiaLviv/Mikolaiv
Rosnov
Pantelimon
Mirovjane
Indjija
Engels
Tosno
Kolomna
Uljanovsk
Chelyabinsk
Drogenbos
> 10051 – 100< 50
Headcount per Site
Adhesive Technology Plants Europe (52 Plants)
Bileca
Wrzaca
Stavropol
Tbilisi (Georgia)
Novosibirsk
Kapshaghai (Kazakhstan)
Wehr
Norderstedt
Epernon
St. Neots
Hernani
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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Lean Enterprise Europe - Management Team
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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Why?
• We want to coach, train and develop people
• We want to improve all key metrics
How?
• We want to establish a system of improvement based on lean principles and involvement of all employees
• We want to focus on waste elimination to generate customer and shareholder value
How we are doing Lean?Objectives of Lean Enterprise Europe
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
202020
Henkel Production SystemTie-in to Overall Strategy – End-to-End Supply Chain
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
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LE Europe 2016: Short facts
Team lead: 1 Workforce: 8 Sites in Europe: 52
3 Six Sigma trainings
+ support in 460 additional local workshops
50 workshops
workshops in 26 sites
444 travel days
14%
82%
4%
Workshops
VSM
CI WS
Invest
> 1500 participants reached
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Impressions of Lean workhops
October 2, 2017
„It was a great workshop across businesses.“
AM & HPS leadership workshop, Krusevac (Serbia) QCO workshop, Heidenau (Germany)
VSM workshop, Villefranche (France)Liofol workshop, Düsseldorf (Germany)
„Significant productivity increase and space reduction possible: 2 floors instead of 3.“
„The target on productivity increase by 10% can be reached by the improvements found.“
„Time variances of 25% - Why does everyone do it so different?”
1. Kaizen Congress in Serbia, Belgrade
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Agenda
1. Did you know …
October 2, 2017
2. How Continuous Improvement programs work in Henkel...
3. What does it mean to be Regional Lean manager...
1. Kaizen Congress in Serbia, Belgrade
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What does it mean to be Regional Lean manager?
Knowing different people andTechnologies
Sharing of Best Practise
Good ratio between physical and virtual meetings
Intensive usage of new ways of communications, networks…
Recognition – taking them out of their normal work
Celebrating small wins
Actions and Result belong to local team!
Work not harder, but smarter and safer
Knowing different people andTechnologies
Sharing of Best Practise
Good ratio between physical and virtual meetings
Intensive usage of new ways of communications, networks…
Recognition – taking them out of their normal work
Celebrating small wins
Actions and Result belong to local team!
Work not harder, but smarter and safer
Different sub-culture
Way of leadership
Language barrier
Travelling (time, money…)
Virtual meetings
WIIFM
Additional activity - > overload?
Savings, savings, savings…
Different sub-culture
Way of leadership
Language barrier
Travelling (time, money…)
Virtual meetings
WIIFM
Additional activity - > overload?
Savings, savings, savings…
DIVERSITYper location, technologies, nation
LONG DISTANCES
Belgrade Novosibirsk
MOTIVATION OF PEOPLE
GEMBA, GEMBA, GEMBA...
EXPECTATIONS
DIVERSITYper location, technologies, nation
LONG DISTANCES
Belgrade Novosibirsk
MOTIVATION OF PEOPLE
GEMBA, GEMBA, GEMBA...
EXPECTATIONS
1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017
252525
AO Europe Lean Enterprise team
October 2, 2017
„Change is the only constant.“- Heraclitus
1. Kaizen Congress in Serbia, Belgrade
Thank you!
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