LEANINOVATIONMiloš Bugan

BASIC FACTS:

CEIT is a company providing comprehensive, innovative solutions for boosting productivity and efficiency of industrial enterprises.

It offers sophisticated products and services that customers and partners to ensure continued competitiveness.

Since

1998A strong team of

expertsExpert guarantor of

major conferences

Transnational

projects

TACT TIME VS CYCLE TIME ...

WHAT'S THE PROBLEM?

Waiting

Un necessary

movements

Stock

Non quality

Transport

Over production

Over processes

Not in video

REQUEST AND VALUE ...

Value added activities - directly changes the shape or characteristic of the product

/ service based on requirement's of customer

What the customer really want?

LEAN APPROACH ...

Customer requirements

Continuous flow

Pull

Perfection

Customer requirements

Continuous flow

Pull

Perfection

REQUIREMENTS, CAPACITY PLANNING? IMAPACT TO LEAN?

TimeTime

Am

ou

nt o

f

wo

rk

Am

ou

nt o

f

wo

rk

Variation

Flexibility

Strategy

A.

Strategy

B.

Who is customer?

What is expected?

What are the conditions?

Who is customer?

What is expected?

What are the conditions?

Clear answer help as on the future with ...

- Capacity

- Quality

- Timing

- Cost

Clear answer help as on the future with ...

- Capacity

- Quality

- Timing

- Cost

Max. possible

capacity

Strategy

C.

IDEAL CONTINUOUS FLOW

LT = 15 min, VA = 3 min, E= 100%

NON LEVELED FLOW

LT = 21 min, VA = 3 min, E= 68% -> LT>40%

LT = 15 min, VA = 3 min, E= 100%

BALANCING ... PREMISE FOR CONTINUOUS FLOWW

eld

Wel

d

Ass

embl

e

Ass

embl

e

Takt time60 seconds

40 s.

62 s.

46 s.

39 s.

1 s.

Stamp

Wel

d

Wel

d

Ass

embl

e

Ass

embl

e

Takt time60 seconds

40 s.

62 s.

46 s.

39 s.

1 s.

Stamp

We

ld

Ass

em

ble

Takt time = 60 seconds

We

ldA

ssem

ble

We

ld

Ass

em

ble

Takt time = 60 seconds

We

ldA

ssem

ble

TIME STANDARDS ...

5S, SW ...

An

d n

ow

...

An

d n

ow

...

PREVENTION, PROTECTION, REACTION ...

CONTINUES FLOW ...

ASSUMPTIONS, DATA, FACTS ...

KAIZEN AND INOVATION

Time

Effect

Kaizen

Innovation

FOCUS ON THE VALUE ...

Traditional option Different option

Lead time = 3 weeks Lead time = 2,5 days

INOVATION ON LOGISTICS

TOOLS ... PRACTICAL EXAMPLES - LEVEL 2

0%

10%

20%

30%

40%

50%

60%

LR HR ZEN

Chosen representatives from whole production assortment

Dotyková lišta bubna spodná

Dotyková lišta bubna vrchná

Spevňovací držiak bubna

Pružina dvierok bubna PRAVÁ

Pružina dvierok bubna ĽAVÁ

Záves dvierok bubna

Dvierka malé opracované

Puzdro zámku s poistkou

Poistka dvierok bubna

Kryt zámku bubna

Pružina dvierok ĽAVÁ

Pružina dvierok PRAVÁ

Záves dvierok bubna

Motor

Plastový kryt na motor

AC fólia motora

Odparovacia hadica

Spona na uchytenie odparovacej hadice

Plochý remeň

Remenica bubna

Magnetický zastavovač dvierok

Vzdušník

Tesnenie vzdušníka

Ohrievacie teleso

NTC snímač

Transportný kolík

Strieška na AS

Bočnica nádrže

Spona na upevnenie hadica N/Č

Tesnenie EKO gule

Hadica N/Č

Eko guľa

Tesnenie nádrže

Závažia

Spevňovací uholník

Dolné závažie (spodné)

Horné závažie zadné

Horné závažie predné

Závažie remenice

Závažie plné zo strany bočnice

Závažie zo strany motora

Závažie na agregát zo strany nádrže

Štvorcová plastová matica

Zemniaci kábel

Kovový kryt motora

Predná stena

LOGO na prednú stenu

Čerpadlo

Drôtená spona

Výtoková hadica

Držiak veka čerpadla

Veko čerpadla

Izolačná platňa

Zadná stena

Držiak s kotvou

MCU box

Držiak hadice

Príchytka vodičov

Poistka tlmiča

Tlmič

Zadné nohy

DFA analysis

Evaluation of 126 components of representative in DFA analysis.

1

3

9

Critical - minimum

Satisfying - maximum

Achievable points for

each criteria

Potential for improvement

Number of criteria

evaluated while

analyzing each

component: 8

Work analysis

2.1.

3. 4. Line balancing

New non-balanced

assembly procedure

based on outputs of

DFA

Balancing of

new assembly

procedureCreating of new assembly procedure

based on outputs from DFA

SIMULATION AND VISUALISATION

SIMULATION AND VISUALISATION

WHAT HAVE TO BE ...

LEAN PROJECTS ...

1. Lean is not about one

project – its a long way ...

2. Appoint a real leader with

competence

3. Start with small micro

project with high benefits

4. Prepare very good

„marketing“

5. Involve maximum

employee as you can

6. Don't forget – 30% is

about activities, but 70% is

about maintaining

7. Follow PDCA

THANK YOU FOR YOUR ATTENTION:

CEIT, a. s.

Univerzitná 8661/6A | 010 08 Žilina | Slovenská republika

Tel.: +421 41 513 7401 | E-mail: milos.bugan@ceitgroup.eu

www.ceitgroup.eu