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1 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
The
Bosch approach
to Process
Management
2 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Management Processes
Core
Processes
(Value
Adding
Processes)
Strategic Management ChangeManagement
Product
Engineering Process (PEP)
Procurement Production Delivery
Order Fulfillment
Process
Cus
tom
er
Cus
tom
er
Production
EngineeringProductDevelopment
Support ProcessesHuman
ResourcesManagement
PurchasingControllingand Finance
Health Safetyand
Environment
IT Coordination and
Organisation
TechnicalFunctions
Plant Protectionand Security
QualityManagement and Methods
BarP
Process Model:
3 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Order Fulfillment Process:
BPS approach
4 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
TargetsBest In Class
PrinciplesEight general rules, that
describe the BPS philosophy
ToolsEmpowerment in order to
execute the principles
Initial State
Ideal status
• 0 failure• One Piece
Flow• in sequence•
according
to demand
• 100% added
value
” True North”
The
Bosch Production
System:
BPS our success for Lean Production
5 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
BPS Elements for empowering
Value Stream
Design
TPM
Q-
ToolsPoka
YokeKaizen-
WorkshopQuick Change
Over
Consumption Control
Lean
Line Design Ship
to Line
6S
Point CIP
Flow
Oriented
Lay
Out Leveling Cyclical
Material Flow ...
BPS Principles
as Guide LinePerfect
Quality Process
Orientation
Flexibility Pull System
The
Bosch Production
System:
6 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
BarP
BPS success story:
2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
2006
7 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
TPM/5S
VisualisationDefinierte
-
ä ne
Gemeinsame
Aufr ä
Aktionen an
Wochenenden
Since 2006: Pull System through TPM
TPM to stabilize the OEE of all bottleneck processes
Value StreamDesign
TPM
Q-Tools
PokaYoke
Kaizen-Workshop
Quick Change Over
Consumption Control
Lean Line Design Ship to Line
6S
Point CIP
Flow OrientedLay Out Leveling Cyclical
Material Flow ...
Perfect Quality Process Orientation
Flexibility Pull System
TPM
8 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
BarP
BPS success story:
2006 2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
9 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Since 2007: Flexibility through Material Flow
Frequency transportation allows continuous stock reduction
Batch size for transport = 1600 Batch size for transport = 120
Value StreamDesign
TPM
Q-Tools
PokaYoke
Kaizen-Workshop
Quick Change Over
Consumption Control
Lean Line Design Ship to Line
6S
Point CIP
Flow OrientedLay Out Leveling Cyclical
Material Flow ...
Perfect Quality Process Orientation
Flexibility Pull System
Cyclical
Material Flow
10 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
BarP
BPS success story:
2006
11 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Since 2008: Transparency through 5S + Safety = 6S
6S as must
for
BPS
Value StreamDesign
TPM
Q-Tools
PokaYoke
Kaizen-Workshop
Quick Change Over
Consumption Control
Lean Line Design Ship to Line
6S
Point CIP
Flow OrientedLay Out Leveling Cyclical
Material Flow ...
Perfect Quality Process Orientation
Flexibility Pull System
6S
12 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
2006
BarP
BPS success story:
13 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Since 2009: Associate Involvement -
empowering the entire organization
Training, involvement and motivation as success factor
Trai
ning
Top
Dow
nTraining B
ottom U
p
PM
VSMgr
Department Manager
Groupleader
Teamkoordinater, Planer, Teamleader
Workers
Training for Managers
Shopfloor
Management Cycle
Leveling and Pull
Training for Planer
Shopfloor
Management Cycle
Standards for TeCo
and Tele
Standards at Shopfloor
for workers
14 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
BarP
BPS success story:
2006
15 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Since 2009: Associate Involvement Management as Mentor in
daily work
I Know
it
I do it
I Lead
it
I teach
it
Management
Associate
Target
Man
agem
ent T
op D
own:
-Dev
elop
men
t of t
he V
isio
n-T
arge
t set
ting
-Rel
ease
of r
esou
rces
Managem
ent Bottom
Up:
-Support em
ployees to find solutions
-M
entor -M
entee
16 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2010200920082007
• Integration BPS-CIP
• CIP on shop floor
• Linea Gialla
• VSD Vision• CIP in al
direct areas• Cyclical
Material Flow
Training onshop floor:• Working
According to Standard
• Shop-floor Manage- ment Cycle
• Pull-system stabilisation
• Ship to Line roll-out
• Reinforce bottom-up processes
Training onshop floor:• Planners• Quick
Change Over
• System CIP to Point CIP
• Lean Admin Review
• Training blue collar: System CIP to Point CIP, Leveling
2011
TPM
CyclicalMaterial Flow
Reinforce5S
Training program for all leaders and workers
Leaders as Mentor
From
System CIP to Point CIP
BarP
BPS success story:
2006
17 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Leaders drive with Speed the Improvement Process
4 System CIP Workshops per year
Duration 2 days
Participants:
PM (PT, PC), VSMgrs
Department Managers, Group Leaders, Planners
First line shop floor manager (Foremen)
External Fresh Eye
Content of the System CIP LIVE Workshop:
Customer Requirements 30’ Plenum
Business Requirements, current/target state 30’ VSMgrs
“Go to Gemba”LIVE, VSM/Bubble Diagram 180’ 7 Workgroups
Development VSD/Bubble Diagram 180’ 7 Workgroups
Definition of projects including KPIs
and Tree 120’ 7 Workgroups
Roadmap 180’ 7 Workgroups
Release of projects by PM (PT,PC), VSMgrs 90’ Plenum
Since
2010: Continous
Improvement
through„From
System CIP to Point CIP“
18 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Positive experience:
A Production System is a change of mindset:
If you decide to do it, no doubt
JUST DO IT
The Production System isn‘t a Sprint, it is a Marathon
Leaders: I can lead it
Involve the whole organization
Start consequently with 6S
No Production System without 6S
Deployment and Training through the entire organization
19 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Support Processes:
Lean Administration approach
20 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
BarP
Lean Administration –
VS visualization:
20
Flusso
di
informazioniVSM = modello
“swimlanes”
21 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2013201220112010
• Lean Administrati on starts
• Basic training for managers
• Training for Lean experts
• All the main processes are mapped (VSM)
• Training for Lean referents
• Redesign of several key processes (VSD)
2014
Roll-out
Process
mapping
VSDiA
2009
BarP
Lean Administration:
• Organization• Strategy• Vision• WS• Training
Redefinedapproach • Point CIP at
office 100% installed
• Competence level 4 for managers
CIP running • Improvement
process managed at lowest level (employees, planers)
• higher level assures a role of mentor
High maturity level
22 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
Since 2012 –
Redefined approach:
Revised strategy and long term vision
New department fully dedicated to Lean Administration
Structured VSDiA
projects to assure :
Reasonable duration (4 to 8 months)
Adequate and stable results
Put the basis for Lean Administration success story
23 BarP/ADM | 18/05/2012 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Salone
d‘
Impresa
-
Venezia
18.05.2012
Diesel Systems / Chassis Systems Control
2013201220112010
• Lean Administrati on starts
• Basic training for managers
• Training for Lean experts
• All the main processes are mapped (VSM)
2014
Roll-out
Process
mapping
VSDiA
2009
BarP
Lean Administration:
• Organization• Strategy• Vision• WS• Training
Redefinedapproach • Point CIP at
office 100% installed
• Competence level 4 for managers
CIP running
High maturity level
• Training for Lean referents
• Redesign of several key processes (VSD)
• Improvement process managed at lowest level (employees, planers)
• higher level assures a role of mentor