The Production Lift -a national support model for sustainable lean
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From Johpomek AB FromScana Steel Booforge AB ”The Production Leap” – a national support program for sustainable lean development in SME:s Partners: Financers: Stakeholders: Programme objectives Participating companies will increase their production expertise develop efficient production continue their improvement work Stronger supply chains A national structure to support and develop production excellence Regional presence National coordination: Swerea IVF contract part to the funders, programme director, co-ordinates the coaching activities Chalmers co-ordinates the education at the different universities Presence in eight regions: Regional leaders from eight universities Cooperation with regional and local company networks, Industrial Development Centres and consultants Three main areas Inspiration and knowledge Education Coaching Education 3845 12 Lean production for practicians (7,5 ECTS) 46 39 22 14 32 8 coordinated universities active hosts 24 15 41 21 42 33 13 9 14 3 23 18 2 31 19 6 17 7 5 20 35 2008 2009 43 34 40 10 44 36 11 2007 2010 2011 8 16 37 Coaching – Key principles for change Management involvement, “walk the talk” Building change capacity (teach the teacher) Learning by doing Empowerment Long-term thinking Standardized methods Continuous improvement within Produktionslyftet Pilot companies 2007 1. AB Furhoffs Rostfria 2. Autotube AB 3. Danielson Sverige AB 4. HT Svarv AB 5. Hörberg Petersson Tronic AB (HP Tronic) 6. Johpomek AB 7. Kockums Maskin AB 8. PlymoVent AB 9. Rapid Granulator AB 10. Scana Steel Booforge AB Spring 2008 Autumn 2008 2009 23. AB Motala Verkstad 24. AQ Lasertool AB 25. Dormer Tools AB 26. Eco Log Sweden AB 27. Elos Medical AB 28. ESBE AB 29. Eskilstuna Elektronikpartner AB (Eepab) 30. Westbaltic Components Töckfors AB 31. Luxo Sverige AB 32. PartAB 33. New Store Europé AB 34. Voith Turbo Safeset AB 32 4 35. WR Controls AB (WRC) 64 86 11. AB Mönsterås Metall 12. Emballator Lagan Plast AB 95 104 63 13. ExTe Fabriks AB 8 49 61. AB Momento 14. Gnotec Mefa AB 88101 62. AB Strängbetong 15 85 15. Indexator AB 105 63. Alimak Hek AB 99 16. Knäreds Werkstads AB (KWA) 64. Betongmästarna Sverige AB 87107 17. Mekanotjänst i Järvsö AB 65. Camfil Farr Power Systems AB 18. Nimo-Verken AB 66. Cryo AB 19. Proxy Electronics AB 67. Edita Västra Aros AB 13 34 51 20. Roplan AB 68. Faiveley Transport Nordic AB 17 45 21. Setrab AB 69. Falkenberg Graphic Media AB 26 22. Skaraverken AB 100 70. Fricweld AB 54 92 71. Husqvarna Manufacturing Sweden AB 30 44 77 46 94 72. Kraftelektronik AB 70 50 52 106 56103 73. LK Armatur AB 90 83 78 85. Element Six AB 62 67 102 74. Mastec Components 79 86. Duroc Special Steel AB 10 29 20 76 75. Nolato Polymer AB 82 53 87. Permobil Produktion AB 72 61 18 76. Norautron AB 59 74 88. Nord-Lock AB 98 27 81 22 77. Norma Precision AB 66 33 65 43 23 24 89. Konstruktions-Bakelit AB 2 808447 1 48 58 78. Scana Steel Björneborg AB 90. DynaWind AB 14 39 40 79. Tebex Cable Assemblies AB 25 69 91. Modul-System AB 919 35 28 55 80. Villeroy & Boch Gustavsberg AB 75 16 3 96 31 92. Nya Arvika Gjuteri AB 37 93 5 11 81. Westcoast Windows AB 38 108 73 41 93. Waco Jonsereds AB 12 36 82. Jensen Devices AB 19 68 6 94. Kitron AB 21 71 7 83. Zetterbergs Industri AB 89 57 95. Gäddede Elektronik AB 97 84. UBAB Ulricehamns Betong AB 96. Rudhäll Industri AB 2010-2011 Coached companies 2007- 36. Bostik AB 37. Carlsson & Möller AB 38. Diab AB 39. Emballator Ulricehamns Bleck AB 40. Finnveden Gjutal AB 41. Finnveden Metal Structures AB 42. Gnotec JV AB 43. Hannells Industrier AB 44. Hiak AB 45. Huddig AB 46. Klässbols Linneväveri AB 47. KWH Pipe Sverige AB 48. Kvillsfors Fönster AB 49. Lövånger Elektronik AB 50. Maxidoor AB 51. Mekanotjänst i Hudiksvall AB 52. Nobel Biocare AB Produktion 53. Nolato Cerbo AB 54. Ostnor AB 55. Press & Plåtindustri AB 56. Scana Steel Söderfors AB 57. Smekab AB 58. Tranås Rostfria AB 59. Westbaltic Components AB 97. Swegon AB 98. Fiskeby Board AB 99. Mekanotjänst i Ö-vik AB 100.Mora of Sweden AB 101.Strålfors Tandsbyn AB 102.Arkitektkopia AB 103.Öhlins Racing AB 104.ÅMV Production AB 105.Jonsson & Paulsson Industri AB 106.Bengt Perssons Bokbinderi AB 107.Fromells VIP-teknik AB 108.Micropower Invest AB Coaching methodology – ”The wave” Continous improvements Consensus & propulsion • • • • • Challenges & ambitions Guiding principles Action plan Methods KPIs & goals Different methods , e.g. • Improvements groups • Visualization • Value stream mapping • Flow orientation • 5S • Quality • Standardized work • Measurement • SMED • etc Deployment Levelling Line organisation Pilotuse Deployment & understanding Pilot flow (or pilot group) Workshop Takt kept with puls meetings Propulsion & learning Prepare Start Steering group 6 12 18 months Organization for change Job requestor GM Management Team Support functions Dept. Dept. Dept. Dept. Group Group Group Group Pilot flow Group Work group Implementor Test pilots Group Group Group Group Steering group Union rep. • Drives the work • Owner of action plan • Strong connection to management • Well rooted in the organization • Examples of the most important challenges • Want to learn & experiment • Good chance of success • Possible to measure effects • Potential of becoming ambassadors • Operate task oriented together • Has authority and respect • Keeps direction and speed • Takes direct action • Gives clear missions • Communicates frequently with management • Takes autonomous decisions • Solves problems • Communicates a lot Start: Establish consensus and propulsion Establish takt with pulse meetings & pulse board Establish pilot flow Action plan KPIs & goals Targets Workshop Homework Describe challenges and ambitions Action plan 1. 2. 3. 4. 5. 6. Guiding principles Lean introduction Lean & PL’s work methods Week: 1 Management of change Lean, learning & change 3 Goals & strategy Flow mapping Targets in Challenges and relation to Lean needs in the flow 7 5 10 Completion Consensus Road map 9 Plan for action Ready for implementation 11 Coaching methodology – ”The wave” Continous improvements Consensus & propulsion • • • • • Challenges & ambitions Guiding principles Action plan Methods KPIs & goals Different methods , e.g. • Improvements groups • Visualization • Value stream mapping • Flow orientation • 5S • Quality • Standardized work • Measurement • SMED • etc Deployment Levelling Line organisation Pilotuse Deployment & understanding Pilot flow (or pilot group) Workshop Takt kept with puls meetings Propulsion & learning Prepare Start Steering group 6 12 18 months New operation methods: Establish change in the whole company Continuous improvement Autonomous in the whole company Different methods , e.g. Many can • Improvements groups • Visualization • Value stream mapping • Flow orientation • 5S • Quality • Standardized work • Measurement • SMED • etc Own ability to implement WS Coach 4-8 hrs Some can Pilot flow (or group) Coach Continuous follow-up and support WS Steering group Work group 1-4 hrs No one can 12 Av företagen bedömda effekter vid uppföljningsbesök Answers on a direct question Andel som av de som svarat som uppger stor resp viss effekt i resp kateogori Very positiv Mycket positiveffect effekt Positive effect Positv effekt One year later in 26 companies 0% 20% 40% 60% No. of answering Antal företag companies som svarat 80% 100% ↓ Produktivitet Productivity 20 Kvalitet Quality 18 Leveranssäkerhet Safe deliveries 18 Throughput time Genomloppstid 17 Inventory turnover Lageromsättning 17 Work situation Arbetssituation 16 Appreciated effects:effekter vid uppföljningsbesök Av företagen skattade Mean value ofavPL’s influence in categories i resp kateogori Medelvärde skattad effekt av Produktionslyftet 0% 10% 20% 30% 40% 26 besökta företag No. of answering Antal företag companies som skattat ↓ 50% Högre produktion Increased production per worked hour per arbetstimme Minskning Decreased quality problems kvalitetsproblem Färre sena Fewer late deliveries leveranser 12 Decreased throughput time Minskad ledtid 12 Ökad Increased inventory turnover lageromsättningstakt 8 8 9 26 besökta företag www.produktionslyftet.se Partners: Financers: Stakeholders:
