Ständige Verbesserung Darstellung alle Kennzahlen und Ziele im „Management Cockpit“ Jahresplan über Workshops, die die Kennzahlen verbessern sollen © TRW Automotive Hold<strong>in</strong>gs Corp. 2011 Verfolgung durch das Management 16 © TRW Automotive Hold<strong>in</strong>gs Corp. 2009 Workshops Productivity Improvement © TRW Automotive Inc. 2006 Kennzahlen <strong>der</strong> L<strong>in</strong>ie Lean action plan 2011 Lean activity : workshop plann<strong>in</strong>g & people <strong>in</strong>volvement EBS: Plant Koblenz ACT Plann<strong>in</strong>g workshop 2011 Current Improvement % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 QUALITY Improvements Plant Pilote UAP situation opportunity change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 MC/As Cleanl<strong>in</strong>ess Master Cyl<strong>in</strong><strong>der</strong> Assy ACT + Mach<strong>in</strong><strong>in</strong>g Hall1 SV? 2 sy Assy Assy Assy Assy Assy Assy Curr. Sit. - Impr.Opportunit % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 HOSHIN Workshops Plant Pilote UAP PPH y <strong>in</strong> PPH change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Improve PPH 7585 (Assy Booster) Thomas Krause Assy 3 Improve PPH 7528 (Assy Valve Control) Thomas Krause Assy S Improve PPH STIWA/8114 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Thomas Krause Assy S Improve PPH 7553 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Thomas Krause Assy S Improve PPH 7526 (Assy Valve Control) Thomas Krause Assy S Improve PPH 7504 (Assy Booster) Thomas Krause Assy S Improve PPH 7571 (Assy Booster) Thomas Krause Assy S Improve PPH 7596 (Assy Booster) Thomas Krause Assy S Improve PPH 7533 (Assy Valve Control) Thomas Krause Assy S Improve PPH 7572 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Thomas Krause Assy S Improve PPH Logistics (Small Parts) Thomas Krause Assy 3 Improve PPH Logistics (Large Parts) Thomas Krause Assy S Improvement Curr. Sit. - % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 SMED Workshops Plant Opportunity <strong>in</strong> Pilote UAP M<strong>in</strong> change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 M<strong>in</strong> WIP reduction 7585 (Assy Booster) SV Assy S WIP reduction 7533 (Assy Booster) SV Assy S WIP reduction 7571 (Assy Booster) Joachim Schliw<strong>in</strong>ski Assy S Curr. Sit. - % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 Pull Workshops Plant Pilote UAP WIP change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 MC/As WIP Reduction Loop MC to Assy Master Cyl<strong>in</strong><strong>der</strong> S sy ??? Pull DeepDive ??? 7585 (Assy Booster) Lars Wobser Assy S WIP Reduction? Assy Booster Lars Wobser Assy S WIP Reduction? Assy Valve Control Lars Wobser Assy S WIP Reduction? Assy Master Cyl<strong>in</strong><strong>der</strong> Lars Wobser Assy S Curr. Sit. - Improvement % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 OEE Workshops Plant Pilote UAP WIP opportunity change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 TPM standard & Improve OEE 7585 (Assy Booster) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7533 (Assy Valve Control) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7596 (Assy Booster) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7571 (Assy Booster) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7532 (Assy Valve Control) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7528 (Assy Valve Control) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7504 (Assy Booster) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7542 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Kurt Wenig Assy S TPM standard - implement and tra<strong>in</strong> 7553 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Kurt Wenig Assy S 5 S Workshops Plant Curr.Sit - <strong>in</strong> % Kennzahlen nach Bereich Def<strong>in</strong>ieren <strong>von</strong> Schulungen % of Jan 11 Feb 11 Mrz 11 Apr 11 Mai 11 Jun 11 Jul 11 Aug 11 Sep 11 Okt 11 Nov 11 Dez 11 Step Target Pilote UAP change 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Reorganize Work Area 7572 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Joachim Schliw<strong>in</strong>ski Assy S Reorganize Work Area 7532 (Assy Valve Control) Kurt Wenig Assy S Reorganize Work Area 7585 (Assy Booster) Stefan Merten Assy S Reorganize Work Area 7542 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Joachim Schliw<strong>in</strong>ski Assy S Reorganize Work Area 7528 (Assy Valve Control) Kurt Wenig Assy S Reorganize Work Area 7571 (Assy Booster) Stefan Merten Assy S Reorganize Work Area 7553 (Assy Master Cyl<strong>in</strong><strong>der</strong>) Joachim Schliw<strong>in</strong>ski Assy S Reorganize Work Area 7533 (Assy Valve Control) Kurt Wenig Assy S Reorganize Work Area 7596 (Assy Booster) Stefan Merten Assy S Reorganize Work Area 7526 (Assy Valve Control) Joachim Schliw<strong>in</strong>ski Assy S Reorganize Work Area 7504 (Assy Booster) Kurt Wenig Assy S Legende: S Start workshop # OP participat<strong>in</strong>g 0 3 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 action plan on go<strong>in</strong>g # Op plant 104 backlog, delay % of total OP 0,0 2,9 4,8 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 7,7 <strong>in</strong> place, impact sav<strong>in</strong>g 9 © TRW Automotive Hold<strong>in</strong>gs Corp. 2011 Aktuelle und historische Werte über z. B. Qualität, Ausbr<strong>in</strong>gung, Produktivität auf Tagesbasis Lean <strong>in</strong>dicator Lean <strong>in</strong>dicator presentation 7 © TRW Automotive Hold<strong>in</strong>gs Corp. 2011 Wochen- und Monatswerte aller E<strong>in</strong>zelkennwerte je Bereich. Farbliche Kennzeichnung <strong>der</strong> Trends Wochenplanung über Schulungen. Betrachtung <strong>von</strong> Mitarbeitere<strong>in</strong>b<strong>in</strong>dung 12
Zusammenfassung • Starke Mitarbeitere<strong>in</strong>b<strong>in</strong>dung durch vollständiges Vertrauen auf Aufschreibungen <strong>der</strong> Mitarbeiter Es gibt nur e<strong>in</strong>e „Wahrheit“ • Verbrauchssteuerung durch manuelle Kanban-Regelkreise <strong>Kunde</strong>nbedarf sofort ersichtlich • Alle Informationen und Aktionen s<strong>in</strong>d am Ort des „Problems“ vorhanden Sofort erkennbar: „Fließt das Material, o<strong>der</strong> fließt die Information?“ Beispielkennzahlen 2005 2011 Arbeitssicherheit 2 pro 200.000 Mitarbeiterstunden © TRW Automotive Hold<strong>in</strong>gs Corp. 2011 0,7 pro 200.000 Mitarbeiterstunden Verbesserungsvorschläge 1 pro Mitarbeiter 6 pro Mitarbeiter Qualität 15 ppm 8 ppm Interne OTD 85% 96% 13
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