Autoliv’s Culture of Continuous Improvement 2012 AME Champions Club... · Autoliv’s Culture of...

Driven for Life

© Autoliv Inc., All Rights Reserved. / INTERNAL

Autoliv’s Culture of Continuous Improvement:

Our 17-year journey and how we “stay sharp”

September 2012Thomas Hartman

© Autoliv, Inc. All Rights Reserved. / INTERNAL / LocCode-AuthorInitials-MMMYYYY-Filename -

Our visionTo substantially reduce traffic accidents, fatalities and injuries

Our missionTo create, manufactureand sell state-of-the-art automotive safety systems


Our ValuesLife - we have a passion for saving lives.

Customers - we are dedicated to providing satisfaction for our customers and value for the driving public.

Employees - we are committed to the development of our employees’ skills, knowledge and creative potential.

Innovation - we are driven for innovation and continuous improvement.

Ethics - we adhere to the highest level of ethical and social behavior.

Culture - we are founded on global thinking and local actions.

We Care


Autoliv in Brief

Sales and technology leader

Sales: US $8.2 billion

Fortune 500 company

Sales to all major vehicle manufacturers

More than 80 facilities in 29 countries

Technical centers in 9 countries with 20 crash test tracks

~48,000 associates whereof 4,400 in R,D&E

RoA

38%

Japan Europe

31%

Americas

10%

12%9%

China


Sales by Customer - 2011

Others


Autoliv in the World

USA

Mexico

Brazil

Australia

South Africa

EUROPE• Estonia• France• Germany• Hungary• Italy• Netherlands• Poland• Romania• Russia• Spain• Sweden• Turkey• UK

India

ChinaJapan

Indonesia

Canada

S.Korea

Malaysia

PhilippinesThailand

TaiwanTunisia


Complete Safety System Supplier

Vision systemInflatable curtain airbag

Passenger airbagPedestrian protection

Night driving assist

Satellite sensorDriver assist radar

Knee airbagPelvis restraint cushionSteering wheelDriver airbag

Side impact sensor

Electronic control unit andBrake control/ESC

Side airbag

Seatbelt systems

Rear-side airbag

Far-side airbag

Battery disconnect switch

Extra belt

Anti-whiplash system


Active Safety Functions

Adaptive Cruise Control Function: autonomously control engine output and braking.

Queue Assist Function: governs braking and acceleration.

Collision Warning Function: alerts the driver, prepares the active seatbelt, puts the brakes in an alert mode.

Collision Mitigation Function: autonomously brakes the car.

High/Low Beam Assist Function: automatically switches between high and low beam.

Traffic Sign Recognition Function: a symbol of a road sign appears in the instrument cluster or on a Head-up display.

Lane-Change Assist Function: alerts the driver by lighting the warning indicator on the appropriate side.

Road/Lane Departure Assist Function: alerts the driver with acoustical or haptic warnings.

Pedestrian Detection/Warning Function: warns the driver or even autonomously brakes the car.

Cross-Traffic Assist Function: warns the driver ofcross-trafffic by acoustic alert.


Active Safety- order intake supports 30% market share target by 2015

E-ClassB-Class

Charger 300DurangoTown & Country TouranGrand Cherokee

Odessey

MDX

TL

RDX

R-ClassC-Class S-Class

~ 88% CAGR

GL-ClassM-Class


IndustryWeek’s Best Plants

Autoliv North America Locations

AMM

Matamoros, Mexico

Products: Molded & Leather wrapSteering Wheels

Autoliv Matamoros

18 Facilities, 3 Countries:Airbag AssemblySteering Wheel AssemblySeatbelt AssemblyInflators (incl. Pyrotechnics & Squibs)CushionsCover MoldingWebbingElectronics3 Technical CentersService parts


What We Do

V:\1omcd\video


How do we Sustain Improvement?

Make it personal!


Over 25,000 lives are saved

every year by Autoliv’s products.

Your Life. Our Life’s Work.


Prom night crash: son of Paul James – (no injuries)


All Airbags Deployed – son of Sherry Vasa (No Injuries)



Set Clear Expectations to Maintain Focus


Autoliv will lead the way……through Perfect Quality in All dimensions – Q5

Behavior



Keep it Simple!


Team Kaizen Suggestion Process

______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Name:_____________________ Date:___/___/___Kaizen #________________

Line/Dept.:___________

______|______|______

____________ __/___/___ ____________ __/___/___

____________ __/___/___

Problem

Suggestion

Shift Review

ImplementationVerification

GraveSwingDay

Signature Date

Standardize

Signature Date

Signature Date

ASP #6216

______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Name:_____________________ Date:___/___/___Kaizen #________________

Line/Dept.:___________

______|______|______

____________ __/___/___ ____________ __/___/___

____________ __/___/___

ProblemProblem

Suggestion

Shift Review

ImplementationVerification

GraveSwingDay

Signature Date

Standardize

Signature Date

Signature Date

ASP #6216

Team has an idea & fills out a new suggestion form.

Team will review suggestion for feasibility and place signatures in the appropriate spot under new.

AMG reviews suggestion and verifies standardization, gives the ok for team to implement suggestion. Card is placed in the in process slot. Team completes suggestion.

Team gives suggestion to AMT for verification of implementation. AMT places card in the complete slot.

APS Tech. will update tracking sheet.

Number of employee suggestions

w1 w2 w3 w4 w5 w6 w7 w8 w9 w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31 w32 w33 w34 w35 w36 w37 w38 w39 w40 w41 w42 w43 w44 w45 w46 w47 w48 w49 w50 w51 w521.69 3.38 5.08 6.77 8.46 10.15 11.85 13.54 15.23 16.92 18.62 20.31 22.00 23.69 25.38 27.08 28.77 30.46 32.15 33.85 35.54 37.23 38.92 40.62 42.31 44.00 45.69 47.38 49.08 50.77 52.46 54.15 55.85 57.54 59.23 60.92 62.62 64.31 66.00 67.69 69.38 71.08 72.77 74.46 76.15 77.85 79.54 81.23 82.92 84.62 86.31 88.00

Fill in the results weekly and draw the graph.

Year

TargetNew sugg.

Implemented

Line/Dept:

02468

10121416182022242628303234363840424446485052545658606264666870727476788082848688909294

w1 w2 w3 w4 w5 w6 w7 w8 w9 w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31 w32 w33 w34 w35 w36 w37 w38 w39 w40 w41 w42 w43 w44 w45 w46 w47 w48 w49 w50 w51 w52

Suggestion is implemented. Great Job Team!

Autoliv Suggestion Process


Focused Workshops

• Team Meeting Times: Tuesday and ThursdayGrave/Days – 5:45amDays/Swing – 1:45pmSwing/Grave – 9:45pm

• AMC/AMG teams are assigned to be on the floor mentoring during the 1:45pm meeting time.

Focus workshop forms available in IBC Operational Standards Database, consisting of:

Why this workshop formAction register with shift approval Focus Workshop Storyboard



Invest in your People to Raise their Skill and Ability


How are your managers spending their time?


The APSU Logo

Goal: Learning by Doing!


APS University Classes

5S / Visual ManagementPDCAPresentation SkillsOperational Availability Smart GoalsStandardsRoot Cause Analysis

YokotenPFMEA6 SigmaProduction AnalysisFlexible LinesAdjustmentsKaizen DevelopmentSafety / ErgonomicTakt Time

Standardized Motion:●Job Breakdown● Production Capacity● SequencingPull System / KanbanProcess vs. Results:One Piece FlowFlexible LineContinuous FlowFrequent DeliveryHeijunkaWaste EliminationFirst Time QualityCompany:● Accounting● Finance

Don’t Judge/ Don’t BlameSMEDMaintenance SystemsAPS in Support AreasMachine DesignJidoka:● Stop & Fix● Separate Man & Mach.Poka YokeDiscipline to StandardsProcess MappingTraining MethodFlexibility & Motivation:● Management SkillsTeam Work


The Importance of Coaching

“Good leaders do not create followers, they create more good leaders.”

Takashi Harada



Get Everyone Involved, not just Operations



Where’s the Beef?


Award-winning Facilities

AME Manufacturing Excellence Award 2011: Brigham City, Utah

The Shingo Medallion2011: Shanghai, China 2010: Queretaro(AQW),Mexico2006: Queretaro(AWM),Mexico

The Shingo Prize2009: Ogden (AOA), Utah2008: Brigham City (IBC), Utah2007: Queretaro(CMX), Mexico2006: Promontory (PRO), Utah2005: Tremonton (ITO), Utah2003: Ogden (AOA), Utah2003: Brigham City (IBC), Utah2003: Ogden Inflators, Utah


50 years of Automotive Safety: 1959 Chevy Impala vs. 2009 Chevy Malibu (40MPH)

malibu vs impala.wmv


1959-era Automotive Safety


2009-era Automotive Safety



Continuous improvement is NOT what we do….

It’s who we are!


Autoliv

Every year, Autoliv’s products save over 25,000 lives

The Worldwide Leader in Automotive Safety SystemsPassiveSafety

ActiveSafety

Autoliv - Safety Systems

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