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THE SOCIETY OF MOTOR MANUFACTURERS AND TRADERS LIMITED PAGE 1
Carl Milbourne
Head of Operations
UYT
An overview of some successful methods and strategies
Carl Milbourne
Head of Operations
Attitude Innovation Heritage People Technology Agility
Corporate Profile or Heritage
600t Tandem Press
1800t Transfer Press
600t Blanking Press
200t Progression Press
Press Facility Overview
600t Progression / Transfer Press
Robot or Manual
Spot Welding = 220
Projection Nut Weld = 60
Automated Mig Weld = 8
Auto Nut Welder = 2
Weld Facility Overview
Accreditations
Evolution to Lean & Agile Manufacturing~
Volume & Investment Trend
Comment:- As shown UYT has had many New Model launches within a short period of time, each one pushing towards a more lean/agile manufacturing base.
Evolution to Lean & Agile Manufacturing ~ First big Milestone
2001
Door apertures
Sun roofs & panels
Tail gates
Bumper Beams
Front Side Frames
Front Damper Housings
Front Bulkhead
Rear Side Frames
Front & Rear Wheel Arches
Advantages: Linear line flow
Interchangeability
Strategy Brief:-
To expand our Weld
Facility by 25%, this
allowed us to increase our
welding capacity and also
accommodate more
complex Structural parts.
“Hang on Parts” “Core Comps” “Complete parts Range”
Evolution to Lean & Agile Manufacturing ~ Capacity Constraint's
2001
2004
2006
Advantages : Quicker cycle time
Increase Output
Flexibility of manpower
Strategy Brief:-
Volume increases
placed pressure on
existing line layout. UYT
increased capacity to
accommodate volume
flex.
Back to back production Front to Front production
2004
Evolution to Lean & Agile Manufacturing ~
Greater Press Portfolio
Advantages: Increase Product portfolio
Increase Output
Competitive Piece price
Strategy Brief:-
Greater press flexibility
was a key driver for
this phase. We
Expanded our Press Facility by 50%
2006
Evolution to Lean & Agile Manufacturing ~ Space Constraint’s
Advantages: Inventory Accuracy
Greater Buffer control
Strategy Brief:-
With the rapid volume
increases UYT
experienced logistical
space was an issue. It
was necessary to
create a ‘Bonded’
warehouse for Int/Ext
product
2010 Advantages Multi Variant lines
Skill Versatility
Floor Space Utilization
Strategy Brief:- Low Volume created an
Opportunity to increase the
flexible capability of our
Assembly lines. With Lines
being more efficient floor
space could be Utilised
towards our vision of “
Innovation line” basically
Benchmark line layout
Evolution to Lean & Agile Manufacturing ~
“Sowing the Seed”
2011 Factory Layout
2012
2013
Current Factory Layout
Evolution to Lean & Agile Manufacturing ~ Innovation Lines
Strategy Brief:-
Amalgamation offered the
opportunity to free issue
the use of equipment into
the new modular lines.
This reduced amount of
new investment required
(£12M)
Phase 1 Phase 2
Phase 3 Phase 4
Evolution to Lean & Agile Manufacturing ~ The transition……
2012
2013
Final layout
2015
2016
Evolution to Lean & Agile Manufacturing ~ Future Bottleneck
Advantages Remain Competitive
Reduce piece part cost
Potential to broaden
our customer range
Strategy Brief:-
OEM’s are driving for a
more efficient car through
weight saving’s. High
strength steels are
becoming an important
factor for this.
However they require
bigger tonnage Press.
3000Ton Press
2008
2011
2012
2013
2014
Tsunami
Thai floods
x 1 fire
UK Storms
Global Recession
Japan tsunami
Key Facts:- Extreme heavy rains in Thailand during
Sept & Oct. 2012. Most expensive natural
disaster in Thai history.
Significant Infrastructure damage
especially Industry.
Thai Floods
Key Facts:- March 11, 2011 - At 2:46pm, a 9.0
magnitude earthquake takes place 231
miles off Japan.
The earthquake causes a tsunami with 30 ft
waves that damage large area’s within
Japan.
Significant impact to Japan’s economic
infrastructure
Key Facts:-
Significant downturn in Global Economy
Sterling devalued by some 30%
Automotive industry heavily effected
(Luxury goods).
Things you don’t plan for…….
Recession
Response to change
“Its not the strongest of the species that survives, nor the most intelligent, but the
one most responsive to change”
2008
Auto Replenishment
Inspection method improvement
1st Line management development
TPM across Plant
Treat unplanned as an Opportunity to Improve-Back to Basics
Quality up activities Parts control improvements Upskill 1st line management
2011
Treat unplanned as an Opportunity to Improve
“ Stronger constitution”
2012
Training Room / Centre
5s on Genba 5’s on Genba
Created a safe working environment Gain ideas from the general associates Promote best practice
Flywheel Used to increase momentum and thereby provide greater stability or a reserve of available power
Mr Mayumi-san was a lone Nut
To Start a Movement :- Must be Public Easy to follow Embraced as equals It takes GUTS to be the first follow No movement without the first follower
UYT Gained Momentum We don’t want to stop this movement!
Manchester UTD
1999 – Won Champions league [Treble] Best team in the World
Attitude/Work Ethic Impact on the Business Skills Courage Irreplaceability
UYT Ltd ‘Class of 2002’
All above started UYT as General associates
Craig Tidman Operator Q /Mgr
Mark Sabino Operator P/Mgr
Dave Ward Operator E/Mgr
Vish Dhand Operator W/Mgr
David Jackson Operator Q/Mgr
Disturbance ” An interruption of that which is Normal or Regular”
Upset
Distraction
Worry
Distress
Interference Annoyance
Hassel
Disruption Irritation
Inconvenience
Trouble
Bother
When things go Wrong look into the mirror to see what you could of done better – Don’t portion blame on others When things go Right look out the window to give praise – Don’t bask in the glory
2014 Target Remove all Disturbance from the Genba No silo Management by Departments Strong Teamwork
The Story so far………………..
2012 2013 UYT
Flywheel Used to increase momentum and thereby provide greater stability or a reserve of available power
Mr Mayumi-san was a lone Nut
To Start a Movement :- Must be Public Easy to follow Embraced as equals It takes GUTS to be the first follow No movement without the first follower
UYT Gained Momentum We don’t want to stop this movement!
Manchester UTD
1999 – Won Champions league [Treble] Best team in the World
Attitude/Work Ethic Impact on the Business Skills Courage Irreplaceability
UYT Ltd ‘Class of 2002’
All above started UYT as General associates
Craig Tidman Operator Q /Mgr
Mark Sabino Operator P/Mgr
Dave Ward Operator E/Mgr
Vish Dhand Operator W/Mgr
David Jackson Operator Q/Mgr
Disturbance ” An interruption of that which is Normal or Regular”
Upset
Distraction
Worry
Distress
Interference Annoyance
Hassel
Disruption Irritation
Inconvenience
Trouble
Bother
When things go Wrong look into the mirror to see what you could of done better – Don’t portion blame on others When things go Right look out the window to give praise – Don’t bask in the glory
2014 Target Remove all Disturbance from the Genba No silo Management by Departments Strong Teamwork
The Story so far………………..
2012 2013 UYT
Thank you for
Listening
Don’t forget to Visit UYT stand (Stall 1)