solvay_live243_p02a04 somEdito

104553
INERGY PRODUCTION SYSTEM (IPS): REPLICATION
OF THE TOYOTA PRODUCTION SYSTEM FOR WASTE
ELIMINATION AND CONTINUOUS IMPROVEMENT
100% ADDED VALUE
FOR THE CLIENT
The goal of a car parts manufacturer such as
Inergy is to supply the right parts, with the
right quality, at the right time, to the right
client, along with the maximum dose of added
value. This goal has taken concrete shape with
the IPS (Inergy Production System). The
ambition that underpins this approach is that
of increasing the company’s competitiveness,
making it an unbeatable supplier at
international level.
It is therefore no coincidence that the IPS
promoters have taken as their inspiration a car
maker that has outstripped the accumulated
profits of Ford, Chrysler and GM, that claims not
to have aged at all in 50 years and that is well
on its way to becoming the number one
worldwide : Toyota.
Like the car maker, Inergy assumed that it
would only achieve its aim if it brought about a
critical change to the way it manages the
material and immaterial flows in order to create
an uninterrupted movement of added value for
its products, day after day. IPS is a standardised
and replicable way of creating added value
currents on all the sites, from the project launch
phase to all the stages of its logistical chain.
This complex and comprehensive process needs:
• the full backing of the employees, regardless
of where they are based;
• the promotion of a culture that values
short-term change;
• a permanent critical overview of the entire
value chain;
• the emergence of a future-looking global
vision;
• stabilisation before moving on to
standardisation and sharing.
> Walter Ceglia; Fortunato Antolin; Thierry Debruille;
Philip Vanderstraeten; Greg Pothoff;
Patrick Tordeur.
> SBU INERGY
104717
INTEGRATED PLANT MAINTENANCE
AND INSPECTIONS WITH MOBILE INFORMATION
TECHNOLOGY AND RADIOFREQUENCY
IDENTIFICATION
MOBILE REVOLUTION:
HIGH TECH MAINTENANCE
IN THE PLANT
Maintaining a plant in good working order
often means setting off on a long trek
to control the thousands of installations on the
site, laden down with a mountain of documents
and plans to ensure compliance. Imagine all the
handwritten notes that must then be typed out
into a file and consolidated with other
information during the days of inspection.
A source of multiple errors that can prove
expensive for the company. Hence the idea of
inventing a mobile industrial system integrated
into the PDA (Personal Digital Assistant) to
provide all the maintenance data throughout
the plant and not only in the offices. The results
of the regular inspections are therefore entered
by the agent into his industrial PDA, which
communicates with the integrated SAP system
where all the maintenance processes are
registered and updated in real time. A High Tech
solution that is already up and running in three
industrial sites: in Tavaux (France) for the
inspection of 1 500 luminous safety installations
immediately detected thanks to the radio
frequencies identification technology (RFID),
in Devnya (Bulgary) for all of the maintenance
operations in the plant, detected during the
inspections, and in Rheinberg (Germany) for the
automation of the maintenance of 5 000 engine
equipment. Many other projects are queuing
up, demonstrating the benefits of this
approach: better reliability of data, permanent
availability, reduction in the risks of error, direct
electronic input…
> Frank Mueller; Michel Adant; Jacques André;
Dominique Boireau; Jean-Noël Daloz; Norbert
Hussmann; Dragomir Iliev; Miroslav Lorinkov;
Daniel Paul; Yves Plagny; Martin Radev;
Thierry Renault; Thomas Wortmann.
> CC SIS
Replicated Innovations
104950
SANDS – SODA ASH NEW DISTRIBUTION SYSTEM
LONG LIVE THE RAIL!
How to avoid the damaging impact of the
increase in transport costs and avoid
losing faraway clients who are placed at a
disadvantage because of the distance
between you? By combining rail and roads,
of course! In fact, the idea is to put the heavy
goods vehicles on the train, just like
passengers put their cars on the train to cross
the Channel. The project also sets out to
keep products in bulk containers close to
isolated or remote clients. A logistics study
has been carried out with an external
consultant and a carrier in Italy. The mission
of the consultant was to develop the
necessary links between the various partners
in the different regions. The carrier, Treni
Italia, is entrusted with the traction of the
carriages. Jointly, the two partners put
together the links in the chain in certain well
defined regions. This new organization is an
excellent response to the challenges facing
Solvay: the taxes on heavy goods vehicles in
Austria and in Germany, which entered into
force in January 2005, the restriction of
driver’s time on the road to 40 hours a week
and the increase in the fuel price. The project
is up and running since January 2005 in Pisa,
Bari and Cuneo (Italy). SANDS is a replicated
innovation originally developed by SolVin.
> Giorgio Barsacchi; Giuseppe Crippa; Bernadette
François; Patrick Balletto.
> SBU SODA ASH
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