Praxisbeitrag im Fachforum:

Systematische Verlustquellenanalysen füreine KVP – orientierte Instandhaltungspolitik

Ein Praxisbericht aus dem Montagewerk BEHR Neustadt

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

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Muffert/AG-P1

Produktion seit 1987

620 Mitarbeiter

450 direkt Gew.MA

170 ind. Gew./Ang.

105.377 qm Fläche

27.734 bebaute

Fläche

Kunststoffspritzerei

Montage

6.500 Anlagen/Tag

Umsatz ca. 240 Mio/€

3 Schichtbetrieb

Willkommen bei in Neustadt

Produkte von Behr-Neustadt: Klima-/Heizungs- und Belüftungsgeräte

Gewicht 10-12 kg

Teile 200-300

Verdampfer

Heizkörper

Gebläse

Varianten 4-16

2 und 4 Zonen

optional PTC

manuell/autom.

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Muffert/AG-P1

Hauptkunden und Lieferanten

München/Regensburg/3er BMW

Dingolfing5er BMW7er BMW

Sindelfingen/BremenMercedes C-, E- u. S-

KlasseMaybach

TorslandaVolvo S 80, V70,XC90

GentVolvo V70, S60

NeustadtLieferanten gesamt: 72

BEHR-Werke: Mühlacker, Pforzheim, Rouffach, Kirchberg, Mnichovo HradisteBosch, Saia, AMP, Burkhardt, Eaton, ...

Lieferanten gesamt: 72BEHR-Werke: Mühlacker, Pforzheim, Rouffach, Kirchberg, Mnichovo HradisteBosch, Saia, AMP, Burkhardt, Eaton, ...

Goodwood/England

Rolls Royce

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Muffert/AG-P1

Montagehalle mit Anlieferzone

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Muffert/AG-P1

Montagelinien W211DC E-Klasse

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Muffert/AG-P1

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Muffert/AG-P1

Montagearbeitsplätze und „Robbi“

Vollautomatischer Prüfplatz

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Muffert/AG-P1

Poka Yoke Abfrage

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

Muffert/AG-P1

RahmenbedingungenVorgaben im Jahr der Umstrukturierung

- Reduzierung der technischen Störungen um 10%

- kein Ersatz von 2 Mitarbeitern (Ruhestand)

- Stückzahlsteigerung um 20%

Instandhaltung

- 13 Handwerker (gute Altersstreuung!)

- 2 Meister (elektr./mech.), 1 Lagerist, 1 Sekretärin (TZ)

- 3 Betriebsmittelbauer

- Abdeckung 3 Schichtbetrieb rollierend

- Maschinenpark ca. 15 Mio €

- Autom. KTL und Fördertechnik

- Lehrlingsausbildung

- Stimmungsbarometer

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

Wer den Hafen nicht kennt,für den ist kein Wind der richtige!

Wer seine Ziele erreichen will,sollte seinen Standort bestimmen!

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Muffert/AG-P1

2

4

6

8

10Ablauforganisation

Aufbauorganisation

Arbeitsplatz- / Arbeitsflussgestaltung

Zeitwirtschaft / Kapazitäts- u. Terminplanung

Materialwirtschaft

Mitarbeiter

Instandhaltungsstrategie

Kennzahlen

Kostenwesen

EDV-Hilfsmittel

Maßnahmen zur Erhöhungdes Anlagennutzungsgrades

In- u. Outsourcingvon Leistungen

Kritische Standortbestimmung (Ist-Situation)- Gesamtbewertung April 2003 der Instandhaltung im Überblick

0 10

Sehr geringeAusprägung

Best Practice

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Muffert/AG-P1

Ergebnis nach Umstrukturierung- Gesamtbewertung September 2004 der Instandhaltung im Überblick

2

4

6

8

10Ablauforganisation

Aufbauorganisation

Arbeitsplatz- / Arbeitsflussgestaltung

Zeitwirtschaft / Kapazitäts- u. Terminplanung

Materialwirtschaft

Mitarbeiter

Instandhaltungsstrategie

Kennzahlen

Kostenwesen

EDV-Hilfsmittel

Maßnahmen zur Erhöhungdes Anlagennutzungsgrades

In- u. Outsourcingvon Leistungen

0 10

Sehr geringeAusprägung

Best Practice

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

16 Verlustarten bei TPM

8 Hauptverluste 5 Verluste menschl. Arbeit 3 Verluste der Produktion

- Anlagenausfälle- Umrüsten & Einstellen- Werkzeugwechsel- Anfahrverluste- Kurzstillstände/Leerlauf- Geschwindigkeitsverluste- Ausschuss/Nacharbeit- Shutdown

- Managementverluste- Bewegung- Linienorganisation- Logistik- Messen/Einstellen

- Energieverlust- Mengenverlust- Formen, Vorrichtungen,

Werkzeuge

Standortbestimmung übertragen auf die Verlustarten:

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Muffert/AG-P1

Definition Aktionsfelder / Projekte in 2004

Zusammenführung

Produktion & Maintenance

kurzfristig (3 - 6 Monate) mittelfristig (6 - 12 Monate) langfristig (12 – 18 Monate)

Realisierungszeitraum

Nutzen

hoch

Regelbesprechungen

100 % Reparaturdaten-

erfassung & Auswertung

Steigerung geplanter

IH-Tätigkeiten

Materiallager im

Montagebereich

Kundenorientierte

IH-Kapazitätsplanung

Autonome IH

Online Datenabruf

in der Montage

Reduzierung MAW

16 Verlustarten

8 Hauptverluste 5 Verluste menschl. Arbeit 3 Verluste der Produktion

- Anlagenausfälle- Umrüsten & Einstellen- Werkzeugwechsel- Anfahrverluste- Kurzstillstände/Leerlauf- Geschwindigkeitsverluste- Ausschuss/Nacharbeit- Shutdown

- Managementverluste- Bewegung- Linienorganisation- Logistik- Messen/Einstellen

- Energieverlust- Mengenverlust- Formen, Vorrichtungen,

Werkzeuge

mittel

klein

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

Vom Aktionsfeld zur praktischen Lösung

Verlustart Aktionsfeld unsere Lösung

AnlagenausfälleAnfahrverlusteKurzstillstände/LeerlaufGeschwindigkeitsverlusteShutdown

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Muffert/AG-P1

BewegungLogistik

MengenverlustFormen, Vorrichtungen,und Werkzeuge

Managementverluste Linienorganisation

Einsatz einer EDV gestütztenStördatenerfassung

Organisationsänderung

Wöchentliche Regelbesprechungpro Prozess

Standardisierte DarstellungStörungen und Aktionen

100%-ige Reparaturdaten-Erfassung &Auswertung

Online Datenabruf

Schichtübergabeprotokoll

Steigerung gepl. Tätigkeiten

Zusammenführung Produktion & Instandhaltg.

Dezentrale IM-Lagerhaltung amVerbrauchsort

Materiallager im Montage-bereich

Offensive „Ordnung und Sauberkeit“ in der Werkstatt

Reduzierung MAW inder Werkstatt

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

16 Verlustarten

8 Hauptverluste 5 Verluste menschl. Arbeit 3 Verluste der Produktion

- Managementverluste- Bewegung- Linienorganisation- Logistik- Messen/Einstellen

Verluste menschlicher Arbeit:

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Muffert/AG-P1

Zusammenarbeit

Was alle angeht, können nur alle lösen,jeder Versuch eines Einzelnen,

für sich das zu lösen,was alle angeht, muß scheitern!

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Muffert/AG-P1

Verlustart: Managementverluste, LinienfunktionMaßnahme: Integration Instandhaltung in die Serienprozesse

BMW / DaimlerChrysler / Ford- Volvo

Neustadt

AG-PWerksleitung

Produktionsprozesse

Montage-Prozess

BMWAG-P12

Montage-Prozess

DaimlerChryslerAG-P11

Montage-Prozess

Ford, VolvoAG-P13

MaintenanceElektrik

Mechanik / AVAG-P14

Leitung Montage /Leitung Instandhaltung

(Vertreten sich gegenseitig)

Wöchentliche Regelbesprechungen- Durchsprache konkrete Störfälle (nach Pareto)

- gemeinsame Maßnahmendefinition- Überprüfung der Umsetzung

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Muffert/AG-P1

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Muffert/AG-P1

Regelkreis Instandhaltung: Bereichsübergreifende Regelbesprechung mit KVP KMT

KorrekturmaßnahmenTeam

Serienindustrialisierung

Einsteuerung in KVP Prozeß

InstandhaltungMechanik/Elektrik

Montagemeisterjew. Prozeß

Verlustart: Managementverluste, Linienfunktion

Problemlösungerforderlich?

FATFehlerAbstellTeam

Qualität

Gestaltungsrichtlinien für Neuprojekte

Sofortmaßnahme

Nachhaltige Abstellmaßnahmen

Regelbesprechung„Pareto"

Maßnahmenliste

IHDatenbankStörungen

Kons

eque

nte

Maß

nahm

enve

rfolg

ung

!

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Muffert/AG-P1

Monatl./ wöchentl.Darstellung derStörungen für jedes Fraktal undZielwertvergleich

Darstellung derTOP 5 Störungen

Definition und Verfolgung- Ursache,- Maßnahme- Prävention- Erlediger- Termin- Status

Standardisierte Darstellung der Störungen

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

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Muffert/AG-P1

Hauptverluste

16 Verlustarten

8 Hauptverluste 5 Verluste menschl. Arbeit 3 Verluste der Produktion

- Anlagenausfälle- Umrüsten & Einstellen- Werkzeugwechsel- Anfahrverluste- Kurzstillstände/Leerlauf- Geschwindigkeitsverluste- Ausschuss/Nacharbeit- Shutdown

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Muffert/AG-P1

Voraussetzung

Wissen über Schadenshistorie und –ursachen

Lückenlose, selbständige, standardisierte Erfassung und einfache, graphische Auswertemöglichkeit aller

Stillstände, Reparaturen, Umbauten, Wartungen, Optimierungen der Produktionsanlagen.

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Muffert/AG-P1

Gemeinsames Ziel

Weg vom „reaktiven“ Reparateurzum

analytischen, planenden, wartungsorientierten Instandhalter!

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Muffert/AG-P1

Gemeinsame Vision

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Muffert/AG-P1

Mittelfristig Verschiebung vonungeplanten zu

geplanten Tätigkeitenaller Mitarbeiter

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Muffert/AG-P1

Fehleranalyse und Maßnahmen pro Arbeitsplatz

Inventar / Benennung/Fehlerbeschreibung/Maßnahme

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Muffert/AG-P1

Wirksamkeit der Maßnahmen pro Arbeitsplatz

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Muffert/AG-P1

Aktuelle Liste der Störungen zur effektiven Schichtübergabe

Aktueller Lebenslauf zur effizienten Reparatur(über „wireless lan“ vor Ort abrufbar)

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Muffert/AG-P1

Vorstellung Produkt und Produktion in Neustadt

Rahmenbedingungen

Kritische Standortbestimmung

Ableitung der Verlustarten und Aktionsfelder

Praxisbeispiele

Erfassung und Reduzierung von

Verlusten aus menschlicher Arbeit

Hauptverlusten

Verlusten aus Produktion

AGENDA

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

Muffert/AG-P1

Verluste menschlicher Arbeit und Produktion

16 Verlustarten

8 Hauptverluste 5 Verluste menschl. Arbeit 3 Verluste der Produktion

- Managementverluste- Bewegung- Linienorganisation- Logistik- Messen/Einstellen

- Energieverlust- Mengenverlust- Formen, Vorrichtungen,

Werkzeuge

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Muffert/AG-P1

Layout und Materialfluss / layout and material flow

Leergutempty cage boxes

Lager/Versand

stock/delivery goods

Kunststoff-Spritzerei

19 Spritz-maschinen

moldingdepartment

Bürosadministration

Wareneingangincoming goods

Lager Produktionsmaterialproduction material stock

Fond H&B 1. Stock

Betriebs-mittelbau

Werkstatt

vorher: Lager IH-Ersatzteile zentral:

Band2

Band5

Band6

Ban

d1Band

10

Band3

Band4

Band7

9(3)

9(1)

9(2)

Band8

WU

WU

Kanb

an

WU

23

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Muffert/AG-P1

KVP bei Behr in Neustadt - Methoden der Organisationsentwicklung

Kaizen

TPM/BEMIS

Fertigungsablauf- und Arbeitsplatz-analyse

Gruppenarbeit (GAT)

Kleingruppenarbeit (KGA)

Betriebsklimaanalyse (BKA)

Prozeßkettenanalyse (PKA)

Spaghettidiagramm

Projektmanagement (PM)

Zielmanagement (ZM)

Benchmarking (BM)

Verbesserungsvorschlagswesen (VV)

KVP-Werkzeugkasten

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Muffert/AG-P1

Ziel: Reduzierung unnötiger Wege durch dezentrale Lagerhaltung

Nutzen p.a.:Einsparung 1250

kmoder

225 Std.nur Produktion !

Alt

Neu

Lösungsansatz durch KVP- Workshop mit der Instandhaltung und Lager

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Muffert/AG-P1

Layout und Materialfluss / layout and material flow

Leergutempty cage boxes

Lager/Versand

stock/delivery goods

Produktion

Kunststoff-Spritzerei

19 Spritz-maschinen

moldingdepartment

Bürosadministration

Band2

Band5

Band6

Ban

d1Band

10

Band3

Band4

Band7

9(3)

9(1)

9(2)

Band8

Wareneingangincoming goods

Lager Produktionsmaterialproduction material stock

FondW

UW

U

Kanb

an

WU

23

H&B 1. Stock

Betriebs-mittelbau

Werkstatt

nachher: Lager IH-Ersatzteile dezentral:

KTL

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Muffert/AG-P1

Jeder macht mit !

Verschwendung reduzieren

heißt auch

Ordnung forcieren!

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Muffert/AG-P1

Betriebsmittelbau vorher

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Muffert/AG-P1

Betriebsmittelbau vorher

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Muffert/AG-P1

Betriebsmittelbau nachher

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Muffert/AG-P1

Betriebsmittelbau nachher

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Muffert/AG-P1

Betriebsmittelbau nachher

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Muffert/AG-P1

Betriebsmittelbau nachher

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Muffert/AG-P1

Gesamtbewertung September 04 im Überblick

2

4

6

8

10Ablauforganisation

Aufbauorganisation

Arbeitsplatz- / Arbeitsflussgestaltung

Zeitwirtschaft / Kapazitäts- u. Terminplanung

Materialwirtschaft

Mitarbeiter

Instandhaltungsstrategie

Kennzahlen

Kostenwesen

EDV-Hilfsmittel

Maßnahmen zur Erhöhungdes Anlagennutzungsgrades

In- u. Outsourcingvon Leistungen

0 10

Sehr geringeAusprägung

Best Practice

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Muffert/AG-P1

1,5

1,9

1,2 1,1 1,1

0

0,5

1

1,5

2

2002 2003 2004 Dez 05 kum. Dez. 05

MAW- BetriebsmittelstörungenWerk Neustadt, Bereich - Instandhaltung Montage

in %

Ziel 2005

< 1,2%

Verbesse-rung

um 43%

Kennzahlen 2005

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Muffert/AG-P1

Team – Neustadt in der Behr Zeitung

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Muffert/AG-P1

Ende

Vielen Dank für Ihre Aufmerksamkeit!

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