Upload
truongnga
View
220
Download
0
Embed Size (px)
Citation preview
kaizen.com
13 Abril 2016Museu do Oriente
kaizen.com
EXCELÊNCIA NO
SISTEMA DE
MELHORIA
CONTÍNUASISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015page 3EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Major exporter and employer in Portugal
2 153
516 million €
Sales 2015
Associates (as per 01.01.2016)
0.3 million Car radios
1.0 millionNavigation systems
0.7 millionInstrumentation systems
0.3 millionProfessional systems
5.4 millionSteering Angle Sensors
1.7 millionOther devices (TT / BSH / FP)
Production 2015Braga City Center
PRÉMIO KAIZEN LEAN
2015page 4EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Certifications for Quality, Health, Safety and Environment
ISO/TS 16949
ISO 14001
ISO 50001
EMAS III
ISO 9001
OHSAS 18001
PRÉMIO KAIZEN LEAN
2015page 5EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Product Portfolio 1990 - 2005
2005
Start of production of
electronic
controllers for hot
water boilers
1990
Start of production
for the “Hamburg”
car radio with
cassette mechanism
2001
Start of production of
antennas in Braga
and Vila Real
2004
“Bremen MP 74”, the
first model with
100% mechanical
design from Braga
1990-1995 1996-2000 2001 2002 2003 2004 2005
PRÉMIO KAIZEN LEAN
2015page 6EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Product Portfolio 2007 - 2013
2008
Start of production of
communication
systems for trucks
2009
First production line
for steering angle
sensors for ESP
systems
2013
Start of production of
Instrumentation
Systems
2007
Start of production of
controllers for
Bosch Siemens
household
appliances
Start of production of car
navigation systems
2006 2007 2008 2009 2010 2011 2012 2013
PRÉMIO KAIZEN LEAN
2015page 7EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Product Portfolio 2014 - 2016
2015
Start of production of
Instruments Clusters
with Optical Bonding
2016
Start of production of
2W Instruments
clusters
2014
Start of production of
CCU – Connectivity
Control Unit
2014 2015 2016 …
PRÉMIO KAIZEN LEAN
2015page 8EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Current Product Portfolio
Next Infotainment Gen
System integration
Connectivity
TV/Tuner radio;
PC HW approach (Intel µP)
Integrated CE solutions
Navigation Systems
Smart integration solutions for
entertainment;
Navigation;
Telematics;
Driver assistance.
Instrumentation
Systems
Innovative free programmable
instrument cluster;
Dual-View;;
Head-Up-Displays.
PRÉMIO KAIZEN LEAN
2015page 9EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Current Product Portfolio
Steering Angle Sensor
Innovative systems and functions
for vehicle safety, dynamics and
driver assistance.
House-hold
Electronics
Manufacture of complex
electronic controllers for a wide
variety of different applications.
Control Units Systems
Innovative and pioneering
solutions for room climate and
water boilers.
PRÉMIO KAIZEN LEAN
2015page 10EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Customers in the automotive market
DFM GAC Great WallJAC
Nanjing
PRÉMIO KAIZEN LEAN
2015page 11EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.Key customers in the household appliances market
PRÉMIO KAIZEN LEAN
2015page 12EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS (Bosch Production System): System CIP ApproachCycle of CIP
Target condition is achieved and
stability has been proven. Point-CIP
becomes
Daily Management (monitoring).
Put the focus on a new problem
Reaction to deviations aims on
quick restoration of the
standards.
Perf
orm
ance
Definition of duration in order to
verify the stability
Time
System-CIP Point-CIPSystem-CIP
Project
Daily management
Elements:
Target condition
Process confirmation with high-
frequency on the improvement-KPI-
Level (ideally event per event)
Quick reaction to the cause analysis
Problem solving with verification of
sustainability
Frequent communication according to
the Point-CIP
Elements:
Standard
Process confirmation adjusted to the
frequency and the KPI-Level
Quick reaction with the restoration to
standards (Reset)
Problem solving with the focus on „Reset“
Frequent communication at the Shopfloor-
Management
Pro
ce
sse
s Implementation of new
standards
Definition of the main
focus
Stabilisation of target conditions
Elimination of fluctuations
Implementation of the system inside
the standard
Reaction to deviations
Gathering of dates/facts for the next
System-CIP-Cycle
Business
Requirments
Priorization of topics
Derivation of target
conditions (Deliver,
Make, Source)
Derivation of an
improvement strategy
Development of new
standards
Definition of target
conditions for Point-CIP
(break down of the KPI‘s
to improvement level)
Ta
rge
t
Action control limit
Target condition
validation
PRÉMIO KAIZEN LEAN
2015page 13EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System-CIP WSInputs
Customer requirement Indicators Target analysis
KPI Tree Losses
Inputs from DMM (daily
management meeting)
System CIP projects (Status)
VSM + CIP Flash
Bubble DiagramBPS Assessment – targets 2015BPS Vision 2018
.True North
.Lesson learn last revision
PRÉMIO KAIZEN LEAN
2015page 14EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System-CIP WSOutput
PRÉMIO KAIZEN LEAN
2015page 15EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System-CIP WSTeam – CIP WS
PRÉMIO KAIZEN LEAN
2015page 16EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System – CIP Project and Point CIPFollow up of project by VS Manager
Standards project by project
( Weekly )
Follow-up – KPI / KPR
( Monthly )
PRÉMIO KAIZEN LEAN
2015page 17EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System – CIP Project and Point CIPFollow up of project by SC BPS
When: What: Who:
Team
Available time from team members for the project
Why this project " Business Case "
Project target, mainly KPI improvement and monitoring
Description of current situation
Plan for PDCA cycle ( Timeline max. 3 months )
Presentation of the root causes of KPI Monitoring and KPRs outside of target VS Manager
KPI Improvement and Monitoring - Chart evolution and analysis
Presentation of implemented Standards and approval on the SC BPS
Presentation of the root causes of KPI Monitoring and KPRs outside of target VS Manager
Deviation of standard detected during process confirmation
Non fullfilment of target ( KPI stability criteria )
Problem solving sheet for deviation found (PSS)
What are the new standards to achieve the target
Approval of new standard by SC BPS
During Point CIP
SC BPS - Agenda for system CIP project and Point CIP meetings
First meeting after system CIP Owners
All meetings until Point CIP
(System CIP projets) Owners
Teamleader
PRÉMIO KAIZEN LEAN
2015page 18EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: System – CIP Project and Point CIPTeam - SC BPS
PRÉMIO KAIZEN LEAN
2015page 19EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: Point CIPElements
%
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 53 54 55 Nº de eventos
7 10
Obs. Preencher apenas em caso de standard Nok.
Confirmação da eficácia da PSS
Chefe de linha Chefe de secção
22.05.14
1 x
2 x
Target Condition
Standard NºStandard
inicial
Sim Não
Acão corretiva Resp.Data
Planeada
Data
Implement.
J.EngenhocaTrocar parafuso 2,5 para 3.5 e lacar 22.05.14
Nº do evento/ Desvio ao
standard ( ) OK e ( )
NOK
3 x
4 x
5
Nº do
Evento
NOK
7
PSS
Nº do Evento Nº PSS Data de abertura Data de fechoNº de dias desde a
abertura até ao fecho
10 1 25.05.14 30.05.14
Causa Raiz
Parafuso do fim do curso solto
. .. . . .
.. ... . . . . . .
Department | 29/05/2014 | © Robert Bosch GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Fast Reaction system
1
EscalonamentoLimite de reação
Pull Cord
8
7
6
5
4
3
2
1
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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Dias
Sim Não 19 20 21 22 23 26 27 28 29 30 2 3 4 5 6
1 X
2 X
3 X
4 X
DiaNº do
StandardDesvio identificado
23 1 Temperatura encontrada de 28º
Nº
4
23.05.1423.05.14Dimensionamento através do sistema RPPD3
Se não é feito a confirmação do processo ao novo standard justificar como garantir que não há desvios ao standard
Standard
Temperatura do equipamento XPTO = 25º ± 2º
AAAAAAA
BBBBBBB
Todos os pinos de 0.6 foram retirados do stock. Os pinos novos tem cor azul e branco . Antes vermelho e branco. O encaixe para os novos pinos diferente dos pinos 06.Menor diâmetro não permitindo a colocação do pino antigo.
Data real Data planeadaResponsávelCausa/motivo do desvio Acão corretiva
Falha do controlador de medida dos limites. Estava mal dimensionado Joaquim Engenhoca
CW _____ CW _____Nº
Confirmação do Processo
Aplicável ?
Follow - up aos desvios ao processo de confirmação
Pinos de fixação do PCB no Equipamento XPTO de 0.5 mm ± 2%
CW 21 CW 22 CW 23 CW 24 CW 25 CW 26
Regular Communication
Registo de participação na Reunião: VS
DI Mês:
CW DB
E1
/ Fra
ncis
co V
ieira
LOG
_C_P
/ P
aula
Ale
xand
rino
MO
E23
/ D
omin
gos
Vie
ira
TE
F8
/ Dan
iel V
ieira
MO
E26
/ R
ui A
lbuq
uerq
ue
DB
E /
Fer
nand
o T
eles
MO
E /
Ant
ónio
Per
eira
PT PC LOG LOG2 MOE TEF TEF1 QMM1 HSE DBE DBE1
VSM
CR
VSM
DI
VSM
TT
VSM
CC
4
5
SC
26
-01
-20
12
Área: Janeiro
1
2
3
Bosch Production System
1 Type of meeting: Product family Value Stream
2 Objective and purpose:
Follow up of KPI and main improvement activities
3 Participants:
VS manager
VS team
4 Place: Gemba (visualization board)
5 Duration: From…………until…………….
6 Regular date: ……………….
7 Frequency: Weekly
8 Agenda:
Follow up of KPI and action to cover deviations
VS target condition follow up
9 Results:
Focus the resources on the improvement of the VS
Ensure the successful execution of the target deployment
10 Who is informed?
MOE2, DBE and others VS managers
11 Is there a log: OPL
12 Log distribution list: no
13 What are the consequences of the meeting?
STRUCTURED COMMUNICATION
INFORMATION SHEET
Fast Reaction System
Target Condition
Regular Communication
Process Confirmation PSS
PRÉMIO KAIZEN LEAN
2015page 20EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: DMMDaily follow-up of the KPI Monitoring
PRÉMIO KAIZEN LEAN
2015page 21EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
BPS: SavingsFirst revision 2015
473 543 € / monthly
PRÉMIO KAIZEN LEAN
2015page 22EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Prémio kaizen Lean - 201513 de Abril de 2016
Thank you for your attention