AL Consulting Presentation

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Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100% Copyright AL Consulting www.al- consulting.com « Together Speed Up Your Progress » AL Consulting Presentation 2014

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About us: A team of consultants; expert in the method and tools to Speed Up Your Progress. Since 1991, AL Consulting is a Leader in Implementing LEAN System round the world (Management, Manufacturing, Supply-Chain, Development & Offices) ****Some figures at the end of 2013 : *** An improvement from 30 to 200 % of the main KPIs *** 1350 successful projects on the complete LEAN Range *** Missions in all industry sectors : automotive (40%), electronics, chemical, rail, commodities, construction, food, services, furniture… *** More than 13 000 trained people (at all levels of the hierarchy) *** Intervention in Europe, North & South America, East & South Asia, Australia and Africa with 6 spoken languages

Transcript of AL Consulting Presentation

Page 1: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

AL Consulting Presentation

20142014

Page 2: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

2

About us

Some figures at the end of 2013 : An improvement from 30 to 200 % of the main KPIs

1350 successful projects on the complete LEAN Range

Missions in all industry sectors : automotive (40%), electronics, chemical, rail, commodities, construction, food, services, furniture…

More than 13 000 trained people (at all levels of the hierarchy)

Intervention in Europe, North & South America, East & South Asia, Australia and Africa with 6 spoken languages

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Since 1991, AL Consulting is a Leader in Implementing LEAN System round the world (Management, Manufacturing, Supply-Chain, Development & Offices)

A team of consultants; expert in the method and tools to Speed Up Your Progress

Page 3: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Our Characteristics to Speed Up Your Progress

1. We train your people well beyond the LEAN basics, getting Short Term results

2. Empower & Support your Expert Network to achieve your Long Term improvement

3. We bring a Common Understanding of LEAN allowing an easier implementation and in all cultures

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• Convince by doing • Improved Motivation,

Competencies & Communication

• More than 60 improvement ideas / training

• Follow-Up workshops

• Developed Autonomy• Respect of YOUR VISION• Actions aligned with Your

Lean Production System

• Our consultants are able to bridge the Gap from Top Manager to Operators

• They all are Factory Experts with many years of LEAN Practice

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Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

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Our Customers

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By the end of 2008, we have supported more than 245 Plants in 26 countries.

ThyssenKrupp

AND : PEGUFORM - ANOFLEX – HAMELLIN - TYCO ELECTRONICS – RACO – MEDTRONIC - SIEMENS – ST GOBAIN RECHERCHE - ELECTRABEL - INSTITUT RENAULT DE LA QUALITE …

Click to see AL Consulting

mission locations

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Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Our values

Principles for all our missions :

Increased autonomy of all persons involved (Employees, Management, Leaders)

Continuous Improvement Mindset applied during training

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Management Involvement

Shop-floor focus

Cross-functional Teamwork

PDCA Approach

Empowerment & Visual

Communication

SUCCESS

Page 6: AL Consulting Presentation

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Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner to Structure Your LEAN Implementation

Example of Lean-Roll Out in Example of Lean-Roll Out in electrics/electronics industry ( 25 sites )electrics/electronics industry ( 25 sites )

Example of Lean-Roll Out in Example of Lean-Roll Out in electrics/electronics industry ( 25 sites )electrics/electronics industry ( 25 sites )

Define LPSTraining & roadmaps

Plant Evaluation based on Roadmap

Identify LPS Leader

Ge

t re

ad

y July

Oct2006

4 days training LPS leader,

plant manager, indistrialization teams…T

rain LPS Awareness

1 day (Finance, HR, IT, …)

Dec 2006

Workshopsidentification

Roadmap : key improvementsF

oc

us D

ec

. 2

00

6

First Hoshin with AL

Consulting trainer

Workshop with LPS leader

Ac

t

FromJan. 2007

First TPM with AL

Consulting trainer

Workshop with LPS leader

First Pull Flow with AL

Consulting trainer

Workshop with LPS leader

...........

.................

Target :LEAN linked to

needs of operations

LPS ReviewsLPS AuditsLPS Board

LPS Awards.......

6LPS : Lean Production SystemLPS : Lean Production System

Page 7: AL Consulting Presentation

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Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner To Gain Short Term Results

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Recover cash slashing on Inventory

Improve output, avoid costly investment improving equipments up-time

Meet the customer demand improving your flexibility

Get rid of Cost of Non Quality

Get It Done !

Task Force to eliminate waste

‘Get the Savings’ Mindset

A lot of practice and little theory

Action aligned with long term vision

Page 8: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner To Gain Short Term Results

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You don’t have problems. You have GOLD MINES!

It is easy , It is quick, and it works.

Our recipe :

Do not try to improve your added value, you have done that for the last 50 years!

Eliminate instead all wastes within & between processes

Page 9: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner To Deploy Your System

Design & improvement Description Visual communication

TO DEPLOY LEAN THINKING IN YOUR CORPORATION

++

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Your Corporation

Your Corporation

Your Corporation

Your Corporation

Page 10: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner in « Leading and Sustaining the Change »

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Lean Review

Site: Blieskastel Review date: 14-3-2008

Lean leader full time / empoweredCI Plan clear and managed

Prerequisites: Managers autonomous for trainingRoadmap filled in (current / futur)MIFA realizedGAP in placeIdentifed Lean -effects on results

2008 operational targets

2008 LEAN prioritiesForecast:

Should be planned (recommendation):

From: S. Weyh Diffusion: Copy:

-> GAP introduction in injection and on TMAC line -> Hoshin workshop on TMAC line

-> TPM : -> TAMC = pilot lign 100% lean: => workshop Just Necessary (Hoshin + Auto-Quality + SMED) => workshop GAP TMAC + GAP Injection -> Injection: target level 4 in problem solving

Productivity: +5%Customer claims < 8 ppmOTD > 99%

+ Strengths – Weaknesses5S standard in Finishing dept ("Fertigung")Auto-audit 5S (by workers)Correct use of kanban in the whole plantAll TPM topics dealt with in 3 areas : Mikron Cell + Gamma Cell + Somaco

5S standard not in place in LogisticRoad map system to be clarifiedPriority: improvement of performance on EURAMIS lineGAP standards not in place, question marks about it

HPS evolution since last review

Niveau 1 = 0% Niveau 2 = 25% Niveau 3 = 50%

20 % - Kein Fortschrittsplan - Arbeitsstandards sind vorhanden - 5S Denken + Methodik verwurzelt

- Keine Arbeitsstandards - Fortschritt = Innovation allein - Fortschrittsplan, Management einbezogen

20 % - Einstellung stimmt nicht - Fortschritt = Gesch. Führer und Experte - Aktionspläne realistisch und koordiniert

- Aktivitâten nicht richtig verfolgt - Lokale Initiativen, ohne Rahmen - Kommunication "Fortschritt" OK

10 % - Keine 0 Verschwendung Kultur - Hierarchie kennt die 7 Verschwendungen - Erlebte Verschwendung wird erfasst

- Überwachung des Fertigung schwach - Produktivität der Schicht wird verfolgt - Erlebte Verschwendung wird eliminiert

10 % - 0 Tool / Methode zur Reaktivität - Arbeitsstandards vorhanden - Stündliche Verfolgung der Aktivitäten

- Keine Arbeitsstandards -Die "Vorgabezeit Kultur" ist stark - 100% Einhalten der Standards auditiert

40 % - Es wird einfach mit den Fehlern gelebt - Qualitätsmonitoring ist in Ordnung - Kontrolle autonom durch die Fertigung

- Qualitätsaktion = Kontrolle am Linienende - Abarbeitung von Kundenproblemen OK - PB Überwachung / Erfassung OK

40 % - Qualitätsaktion = Qualitätsabteilung - Keine Vorbeugende Massnahmen - Entdeckung vs Entstehung verfolgt

- Qualitätsaktivitäten unstrukturiert - Kontrollanweisungen in Ordnung - Selbst Kontrolle auditiert und effektiv

20 % - Maschinenleistung nicht verfolgt - Anlagenzustand ist in Ordnung - TPM Aktion mit einem Projektleiter

- Instandhaltung = Feuer löschen - Maschinenprobleme werden erfasst - Fertigung zuständig für Anlagenleistung

20 % - 0 Mitwirkung der Fertigung - Zentrale Instandhaltung ist strukturiert - Instandhaltung Niveau 1 durch Team

- Anlagenzustand ist schlecht - Vorbeugende Aktivität ist in Ordnung - MTBF und OEE Verluste verfolgt

30 % - Abarbeitung der Probleme unstrukturiert - Probleme werden erfasst - Problemabarbeitung strukturiert

- Mentalität = Abweichung rechtfertigen - Individuelle Aktionen in PB-Abarbeitung - Einige Personen sind dafür zuständig

30 % - Probleme werden bestens versteckt - Beispiele für guten Methodeneinsatz - PB-Abarb. Standardmethoden

- Methoden zur Problemlösung unbekannt eingesetzt

25 % - Keine Richtlinie, keine Standards bei der - Arbeitsgänge bestimmen das Layout - Rücksicht auf Layout Auswirkungen

der Gestaltung von Arbeitsplätzen, - Einige Flussdarstellungen vorhanden - Beispiele für Flussprioritäten

25 % Fertigungsbereichen und Werk ( Spaghetti Flow ) - Einige individuelle Initiativen zur

- Wichtigkeit des Layouts unbekannt - Einige Standards für Arbeitsplätze Verbesserung des Fertigungsflusses

30 % - MIFA unbekannt - Begriff Durchlaufzeit ist bekannt - Fluss wird regelmässig analysiert , aber

- Fluss ist schlecht - Informationsfluss ist unter Kontrolle ohne spezifische Methode wie MIFA

30 % - Informationsfluss ist problematisch - Fluss Kultur ist vorhanden in der

- Es zählt nur der Arbeitsgang Logistik Abteilung

25 % - Bestand ist das Fundament des Systems - Bestand ist das Fundament des Systems - Tools zur Bestandreduzierung bekannt

- Bestand ist gut - Bestand ist unter Kontrolle - Einige gute Beispiele sind zu finden

25 % - Bestand ist nicht unter Kontrolle - Bewusstsein Bestand = Verschwendung

25 % - Keine Analyse der Volumina - Analyse der mittelfristigen Volumina - Tägliches Arbeitsvolumen nivelliert

- Fertigung soll sich 100% anpassen ( 6- monatige Vorschau ) - Kein Glätten durch Mixen

25 % - Steuerung erfolgt in der Logistiksabteilung - Effektivität dieser Vorschau erewiesen

- Es wird haupsächtlich auf Mängel reagiert

50 % - Pull System ist unbekannt - Einige direkte Verbindungen Kund / Liefer. - Eine Art Kanban mit oder ohne Karten ist

- Planung durch die Zentrale Steuerung - Halbfertige Produkte nicht unter Kontrolle, im Einsatz, dank kleinere WIP Bestände

50 % - Abriss = Planung Überfertigung ist keine Ausnahme - Die Regeln sind klar, und werden

- Ziel ist, Reduzierung des MRP Einsatzes konzequent eingehalten

LUZERN Lean Production System

PLANUNG der FERTIGUNG

KANBAN

PROBLEM ABARBEITUNG

LAY OUT

MIFA / MIFD

BESTAND REDUZIERUNG

VERSCHWENDUNG ELIMINIEREN

AUTO - QUALITY

T P M

KONTINUIERLICHE VERBESSERUNG

STAND AM HALBJ AHRANFANGZIEL AM HALBJ AHRENDE

3.2

1

2 0

VER

SC

HW

EN

DU

NG

3.3

3JU

ST IN

TIM

E

2.1

2.2

2.3

2.4

3.4

3.5

3.1

BEREICH

RegularLean-Reviewsby Corporate

+ AL Consulting

RegularLean-Auditsby Corporate

+ AL Consulting

Lean-Steering Team

at Corporate Level+ AL Consulting

MANAGEMENT OF LEAN

ACTIVITIES AT CORPORATE LEVEL

MANAGEMENT OF LEAN

ACTIVITIES AT CORPORATE LEVEL

Page 11: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner to Develop Lean Thinking

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Entertaining lean games

Entertaining lean games Demanding Shop

Floor training

Demanding Shop Floor training

Training for immediate

actions

Training for immediate

actionsTraining for

immediate results

Training for

immediate results

Don‘t worry, we are here to

support you during your

first trainings on your own!

Don‘t worry, we are here to

support you during your

first trainings on your own!

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Page 12: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Your Partner for Major Cultural Challenges

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Efficient PB-SolvingEfficient PB-Solving

MIFA-SteeringMIFA-SteeringStandardized workStandardized work

Leveling / mixingLeveling / mixing

Operation from: Date:

to:

Takt Time Expected nb parts waiting

61 s

Cycle time

51 s

Expected number of parts waiting

3

Product: panel Process: welding, assembly

Standardized work chart

Machine 4 (Welding)

Station 5 (Inspection)

FP cart12

3

4

5

6

710

8

9

Qualityinspection

Safety

Movement

with part

without part

Productionname:

date:

Methodsname:

date:

Qualityname:

date:

Page 13: AL Consulting Presentation

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Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

The Partner for your People

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Alongside your Lean

System,

a highly structureda highly structured

HR - Involvement HR - Involvement

ProgramProgram,

for the benefits of your

Customers,

Company and People.

Alongside your Lean

System,

a highly structureda highly structured

HR - Involvement HR - Involvement

ProgramProgram,

for the benefits of your

Customers,

Company and People.

DelegationDelegationDelegationDelegation

DevelopmentDevelopmentDevelopmentDevelopment

RecognitionRecognitionRecognitionRecognition

InvolvementInvolvementInvolvementInvolvement

Visual Improvement proposals

Visual Improvement proposals

Page 14: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Trainings with Increased Added Value We bring:

Training aligned with the JPS and the factory objectives

Vision for the Steering Committee to appraise the current situation and to roll out an Improvement Plan

Practical training games & exercises

Clear and easy to use guidelines for self-implementation after training

Coaching to JPS leaders and training participants for their workshop applications

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Page 15: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Testimonies

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“During June 2008, AL Consulting provided production system efficiency training to employees from my division.  As a plant manager, I was impressed by Claude’s ability to balance theoretical with practical exercises and existing conditions.  Our training session included three levels of employees from my plant as well as engineering, safety, and production managers and coordinators from other plants and division headquarters.At the time of the training, our division was consolidating two manufacturing plants.  AL Consulting was able to integrate this real-time activity into the session.  This provided an added dimension to the practical exercises and allowed our employees to learn from the immediate application of their training.”

James Harlan Plant ManagerFaurecia Exhaust Systems US

"I have twice had the pleasure of working with AL Consulting. First was in Indonesia where in 1 week we empowered the local employees to reduce inventory and cut throughput times by an incredible amount. We also achieved the aim of reducing floor space by so much that a proposed large additional workshop bay was not required (saving capital expenditure) and had space for an additional line.The second was in Brisbane where we had a training week for 16 long term professionals, the change in attitude was phenomenal, from sceptics to believers in 4 short days. Everyone going "electric" over the potential improvements - why had we not done this before? The results from this have been sustained and improved upon and I would put this down to the way the training was performed, leading the recipients on a journey throughout the week, using examples that could be easily grasped and held onto, practical and powerful.” I would recommend any company starting their Lean journey to use AL Consulting.”

Mike Wilkes Manufacturing ManagerAreva T&D Australia Ltd

Page 16: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Testimonies

16

Even as a person educated in logistics management, the Hoshin and Kanban training I received from AL Consulting was extremely beneficial.  The team activities truly reinforced the principles that are vital to the successful implementation of these Lean methodologies.

Charles BurtonProgram Manufacturing Leader Faurecia Exhaust Systems" 

« During the past 2 years, AL Consulting has been providing us with good expertise in lean manufacturing,  not only for trainings conducted, but also for projects coached. The co-operation between us is productive. The dedication, professionalism, and results delivered from AL Consulting are impressive. We are becoming more lean and more competitive because of AL Consulting support, and we look forward to working with AL Consulting in the long term.

Ken YinSupplier Development Manager AREVA T&D China

My experience in CD Juarez, Mexico with AL Consulting:

Implenting Lean Manufacturing is a major TOP Management decision , but it is not the only major one. The "HOW" is a key factor to succeed. When I step back and realize this, I can see that using AL Consulting has been the "trigger" to start seeing the change. AL Consulting has provided in my country Mexico real "field" experience and tools; with an excellent cultural understanding and by adapting communication to all levels in organization.Teaching, implementing  and coaching our employees is the structured process to achieve the Continuous Improvement mindset.  Practical and physically involved in each step, AL Consulting provides the guide, the principles and motivates people to learn.AL Consulting is in my opinion a reference in his approach and vision for deploying Lean Manufacturing as a partner for any company. Thank you all AL Consulting team "

Salvador LamasCI Manager Valeo

Page 17: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

Testimonies

17

"AL Consulting support in developing our Supplier Development / Lean Manufacturing training module has been very professional. First training session in India gave significant results through the new layout of one of our production line during the training session : lead time reduction by 68%, manpower reduction by 30%, surface saved 66%. Innovative solutions are already proposed to support us in the deployment of our Supplier Development Program in China, and will be studied soon to start another part of our supplier development program. Adaptability to our needs and activities has always be one of their priority. AL Consulting in few words: Competences, professionalism, customer care and Kaizen spirit"

Mr. Denis Dajno Key Comodities & Supplier Development Director, AREVA T&D

“The VSM process is pragmatic, we can see it directly in the workshop. The training with concrete examples allows to involve all the actors that might have a role in the Flow simplification. This training has made the Management Committee take conscience of the potential progress and starting new workshops. It is a simple tool that we have decided to integrate to our semiannual management review.AL-Consulting’s services have been excellent, the organizer has a very good control of the tool, his knowledge of the industrial world allows him to be credible.” Thierry WipffDirector of Continental Plant

Page 18: AL Consulting Presentation

Reduce Lead Time by 90% Cut Your Rejects Rate by 10 Increase Productivity by 100%

Copyright AL Consulting www.al-consulting.com

« Together Speed Up Your Progress »

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Contact us

André LANGLOIS Consultant, General Director Tel : +33(0)232563400 Fax : +33(0)232564259 Mobile : +33(0)609141202 E-mail : [email protected]

Web : www.al-consulting.com

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