Dromone¢â‚¬â„¢s Lean Journey Presentation - Engineers Ireland Dromone¢â‚¬â„¢s Lean Journey Presentation April

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  • Professional Engineering

    Dromone’s Lean Journey Presentation

    April 2014

    Philip Gillic

    Business System Manager

  • Professional Engineering

    Product Portfolio

    Agriculture Tractor Pick Up Hitch 58% Revenue

    Construction Excavator Quick Coupler 42% Revenue

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    OEM Business

    55% Total Revenue

    OED Agriculture Distributor

    22% Total Revenue

    Customer Portfolio

    Construction Distributor

    23% Total Revenue

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    2015 Company Goals

    Professionalise all levels of the Dromone organisation

    Grow sales profitably to meet 2015 plan

    Protect existing business:

    Quality, Service, Competitiveness

    Exceed industry expectations in:

    Quality, Safety and Environmental protection

    Implement Right First Time principles

    Develop robust supply chain through supplier management

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    Operations

    Excellence

    Right First Time.

    Cost reduction through-

    efficiency improvement.

    Throughput Time.

    Customer

    Management

    Voice of the Customer.

    Sales Margin.

    Key Account Management.

    Supplier

    Management

    Cost Reduction.

    Right First Time.

    Reduced Inventory.

    Engineering

    Design

    New Product Introduction.

    Right First Time.

    Continuous Professional-

    Development (CPD).

    What we have to achieve

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    Phase 1:

    Analysis

    Map Current State & understand major

    issues

    Provide core skills training in Problem

    Solving, Project Management & Lean

    Create High Level Future State Vision

    & Roadmap

    Phase 2:

    Stabilisation

    Eliminate 8 basic wastes & deploy Standard Work

    Introduce RFT principles & effective

    NCR Process

    Improve NPI Process & deploy PFMEA

    Improve performance of

    process constraints & start to reduce

    batch sizes

    Phase 3:

    Process Design

    Develop detailed Future State Map

    Continue to stabilise, deploy standard work,

    reduce batch sizes, & load level

    Modify the Planning process to produce products on EPEX

    Cycles

    Phase 4:

    Introduction

    Phase 5:

    Improvement

    Implement layout

    changes, Kanban &

    Pull Systems

    Deploy Andon and

    Jidoka principles to

    deal with abnormal

    conditions

    Kick off

    improvement

    programme with

    major suppliers

    Introduce Heijunka

    Boards

    Reduce EPEX Cycle

    to collapse

    throughput times

    ../../../../S.A. Partners/Clients/KB Group/KB-U/New Plant Logistics/Implementation Master Plan.xls

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    Feeling the Pain

    Burning Platform

    Value Stream Mapping

    Urgency

    Constraint Identification Data Flow

    Product Flow

    Throughput Time

    Order fulfilment 2.2 months

    The activity ratio was 3.4%

    Constraint Identification

    CNC drilling OEE was 29%

    Batch processing prevailed

    Local functional efficiency

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    Believing In Lean

    Importance of believing

    Senior management & key person confidence

    Clear goals

    Test and learn in safe environment

    Learning and Practice

    Zero Defect Work Shop

    Quick Change Over workshop

    Lead Time Reduction Work Shop

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    Clear Lean Thinking

    Importance of Stable Processes

    Critical thinking skills

    Structure and common language

    Tools and skills

    New Product Introduction Practices

    KT Problem Solving training

    Customer Communication using KT

    tools

    KT Project Management Training

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    Islands of Excellence

    Early success is critical

    Illustration of what “Good” looks like

    Confidence in the process

    Early champion and advocates

    Assembly Area Project

    Physical changes in the area

    Team living the beliefs and behaviours

    Team Leader Champion: Mick Lynch

    Quality Problems Originating In Final Assembly

    2013

    0

    2

    4

    6

    8

    10

    12

    14

    16

    JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC

    Series1 Linear (Series1)

    Standard Time Tracking across Product Family

    900

    1162

    13201380

    840 702 720

    1800

    2949

    400

    90150 200

    0

    500

    1000

    1500

    2000

    2500

    3000

    3500

    1 2 3 4 5 6 7 8 9 10 11 12

    Measurement Number

    S td

    . T

    im e

    i n

    s e

    c o

    n d

    s

    Large Pushback (A)

    Large Pushback (B)

    Small Pushback

    Mousetrap

    Roller

    Vertical

    Acc Assy

    Direct Pack Acc

    K80 Ball

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    Knocking Down Barriers

    New Problems and Challenges

    Challenges strengthen Lean journey

    Vocal and Passive Resistance

    Physical issues: batch size reduction

    Dealing with challenges

    “Call to arms”

    Motivated middle management

    New Process Engineering Team 0 500

    1000

    1500

    2000

    2500

    3000

    3500

    4000

    H o

    u rs

    Wk 25 Wk 33 Wk37 Wk 39 Wk 41 Wk 43

    Welding Constraint Arrears KPI

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    Celebrating Success

    Inspire Transformation

    Motivation for the team

    Reinforce success

    Internal company success

    Secure Employment & Personal

    Development

    New business contracts

    JCB, Volvo Construction

    Equipment, Agco

  • Professional Engineering

    Celebrating Success

    External recognition

    Agco Supplier Quality Award 2012

    Engineers Ireland CPD employer of the year

    National Award 2013

    Regional Company of the Year Award 2013

    National Lean Conference Participation, Dublin

    Castle, Ireland

    IMC 29 Key Note Speaker on Dromone Lean

    Systems Project 2013

  • Professional Engineering

    Summary

    Start of the Lean Journey for Dromone

    Big step in the right direction

    Feeling the pain and believing in Lean

    Clear thinking and knocking down barriers

    Celebrating success

    Positive business and customer impact

  • Professional Engineering