Lean Production Systems Implementation in Germany

Lean Production Systems Implementation in Germany

Lean Production Systems Implementation
in Germany
Univ.-Prof. Dr.-Ing. Uwe Dombrowski
Dipl.-Ing. Isabel Crespo, Dipl.-Wirtsch.-Ing. Stefan Schmidt
31st Conference of the European Academy on Industrial Management
Braunschweig, Germany, 24th-27th September 2009
© IFU
1
Development of Production Systems
today
1900
1920
1940
1960
1980
2000
Artisan/ Manual
1 Production
„Tayloristic“
Assembly Line Work
Technology-oriented
Production
„Classical“
Industrial
Production
Automated
Production
Computer Integrated
Manufacturing
2
Toyota Production System
Lean
Production
LPS
3
© IFU
2
Definition of Lean Production Systems
A Lean Production System (LPS) is…
… an enterprise-specific compilation of rules, standards, methods and tools,
as well as the appropriate underlying philosophy for the comprehensive and
sustainable design of production. An LPS enables an enterprise to meet the
requirements of today´s business environment, taking into account
organizational, workforce-related and economic aspects.
Source: Dombrowski
Philosophy and
Methoden und
Culture
Werkzeuge
3
Methoden und
Methods
and
Werkzeuge
Tools
Ganzheitliches
Produktionssystem
LPS
Goals
… Raum für
Weiterentwicklung
und Anpassung
...
Methoden und
Werkzeuge
The implementation of an LPS is
not just a regular rationalization
project, but a fundamental change
in the organization and culture of
an enterprise.
Source: Salwiczek
© IFU
Structure of Lean Production Systems
...
SG SG ...
k1 k2
...
Method m
...
FA k
...
Tool n
FA 2
SG
kj
Method 2
...
SG
2j
GG i
Tool 1
• Method
...
Method 1
3
SG SG ...
21 22
FA 1
Method 1
Field of Activity
SG
1j
GG 2
Method m
SG SG ...
11 12
Method 2
Sub-Goal
Method 1
2
GG 1
Method m
General Goal
Method 2
1
...
Tool n
...
Tool 1
• Tool
Tool n
4
Tool 1
...
Source: Dombrowski
© IFU
4
Example for the Structure of
Lean Production Systems
1
General Goal
2
Sub-Goal
Field of Activity
Increase in Quality
Increase in Product Quality Reached by
Sustainable Improvement of Processes
TQM/ Quality
Systems
5
3
• Method
Statistical
Process Control
(SPC)
4
• Tool
Quality Control
Chart
Source: Dombrowski
© IFU
Analysis of the LPS Structural Design
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
Au
ftr a
gs
st
Te
ch
no
lo g
ie/
ntie
Further Fields of Activities are:
8 5 S-Housekeeping
9 Standardization
ng
14
Pro
du
ktg
es
tal
tu
13
run
g
12
Pro
ze
s so
r ie
11
elts
ch
utz
llie
eu
er u
ng
/N
ive
nd
ar d
i
sie
r
run
g
un
g
10
Um
w
9
Fe
r tig
un
gs
pro
zes
se
8
Sta
nt
an
ag
em
e
Pe
rs o
na
lm
ue
lles
Viis
TQ
M/
The following Fields of Activities are
part of least 70% of all analyzed LPS:
7
5S
6
TP
M
5
KV
P
4
Ma
na
ge
me
nt
Qu
alit
äts
sy s
t
/K
3
em
e
2
an
ba
n
1
J IT
0%
Gr
up
pe
na
rb e
it
Verwendung
in LPS
of Activities
Use of Field
in GPS
Gestaltungsfelder
- Database 17 LPS global enterprises -
1 Team Work
93 %
2 JIT/ Kanban
87 %
3 TQM/ Quality Systems
87 %
4 Visual Management
87 %
5 Continuous Improvement Process
80%
73%
12 Environment Protection
13 Process Orientation
27 %
6 Total Productive Maintenance
7 Human Resources Management
73%
14 Product Design
13 %
© IFU
67 %
53 %
Leveling/
10 Mixed production
53 %
Technology/
40 %
11 Manufacturing processes
20 %
Source: Dombrowski
6
Current Status of LPS Implementation
- Results of a Nationwide Survey in German Production
Enterprises, August 2007• 27 enterprises in different industry sectors and with different sizes have participated
in this survey.
• 56% of the analyzed enterprises belong to the automotive supplier industry and the
mechanical engineering industry.
Percentage of the
researched enterprises
• 77% of the researched enterprises are large-scale enterprises. Only 22% of the researched
enterprises are small and medium-sized enterprises.
Source: Kessler
40
35
30
25
20
15
10
5
0
70%
No
Implementation is
Know-How
not jet planned
7
Implementation Implementation is Implementation
is planned
running
is concluded
Source: Kessler
Almost all researched enterprises (70%) have implemented an LPS or are in the
implementation phase.
© IFU
Spread of LPS Implementation
Tier n Supplier
Tier 2 Supplier
8
Tier 1 Supplier
Industries
OEM
Automotive Industry
© IFU
Machine Tools
Electrical, Aerospace
and Food Industry
Source: Dombrowski
Successful Enterprises in Germany
Implement Lean Production Systems
Winner!
Winner!
2008 BMW AG, Dingolfing
2008 Festool GmbH, Neidlingen
2007 Siemens AG, A&D AS EWA TOP,
Amberg
2007 Robert Bosch GmbH, Automotive
Electronics Division, Ansbach
Plant
2006 Rational AG, Landsberg/Lech
2005 Cherry GmbH, Auerbach
2004 Siemens AG, Automation &
Drives, Erlangen Plant
2003 Fujitsu-Siemens Computers
GmbH, Augsburg
2006 Siemens AG, Automation &
Drives, Erlangen Plant
2005 Johann Winklhofer & Söhne
GmbH & Co KG, Landsberg/Lech
2004 Siemens AG - Medical Solutions,
Forchheim
2003 Siemens VDO Automotive AG,
Babenhausen
Source: Die Beste Fabrik
Source: Die Fabrik des Jahres
Alle these successful enterprises have implemented a Lean Production System
(or at least parts of an LPS) during the last years!
© IFU
9
Lean Production Systems Implementation
in Germany
Univ.-Prof. Dr.-Ing. Uwe Dombrowski
Dipl.-Ing. Isabel Crespo, Dipl.-Wirtsch.-Ing. Stefan Schmidt
31st Conference of the European Academy on Industrial Management
Braunschweig, Germany, 24th-27th September 2009
© IFU
10