Annual Report 2010 - Knorr-Bremse AG.

RepoRt
59
A unique concept in the rail vehicle industry
One innovative aspect of the new plant, in which the company has invested some EUR 45 million, is
the underlying concept of the “5-day factory”, based on the globally standardized Knorr-Bremse Production
System. The concept involves a wide range of pioneering measures aimed at significantly reducing
throughput times along the entire value chain. In the past a major component like the block
brake would take from 20 to 30 days to complete from provision of the raw materials to final shipment,
but standardization of all production processes at the new factory now means the same process
should take just five days – an improvement by a factor of four.
Ingenious supply chain models
Underlying these improvements is the use of intelligent supply chain models, integrated manufacturing
cells, an in-house surface treatment center, and one-piece-flow assembly lines aligned with customer
cycles. This in turn is facilitated by an ingenious system that ensures optimal integration of
procurement, production, and delivery systems.
Knorr-Bremse has developed a system that precisely assigns all products to a supply model. This is
based on more than just the customary analyses: The “5-day factory” also weights the competence of
each supplier, for example, as well as other aspects with a bearing on logistics, such as volumes.
Focus on customer benefits
By moving to the new plant, Knorr-Bremse is enhancing customer benefits in several respects – first
and foremost through greater flexibility and optimized schedule effectiveness. The closed value-loop
within the company has also been improved and more efficient transportation and handling processes
have further improved product quality.
On a site situated close to the old facility, more than 1,000 employees now work in a modern building
offering over 30,000 m² of production and office space. A combination of selected building materials
and innovative control technology ensures optimum energy use and has significantly reduced the
new plant’s energy requirements and operating costs.
Opening ceremony
High-ranking visitors attended the inauguration of the new Knorr-Bremse Rail Vehicle Systems plant in
Budapest in early July: Both the Hungarian Minister of National Development, Dr. Tamás Fellegi, and
the Chairman of the Supervisory Board and owner of Knorr-Bremse, Heinz Hermann Thiele, were present
at the ceremony.