Finbarr Dowling MAS2011 Presentation

Finbarr Dowling

Managing Director, Siemens Inverters

Finbarr DowlingManaging Director

Siemens I DT MC I Congleton

MAS ConferenceJune 16th 2011

Old Trafford

‘Innovate or Die’

Ted Hoff

A long history of innovation

Who we are

1971 Siemens established at Congleton1991 Designated electronics manufacturing factory1996 GZ ASI 1S HQ1999 A&D SD D Design, Manufacture & Technical CS

Total land area:-21,000 m2

Building area (office + production):-12,000 m2

Employees: (510)

Congleton’s manufacturing technologies and products

Sinamics G120 Modular

Micro MasterIntegrated

Sinamics G110

Surface Mount Technology

Through hole Technology

PCB Test Technology Coating Technology Mechanical Technology

Sinamics G120D

Our Competencies

Electronic production of Industrial products in the area of low complexity, high volume Variable Speed Drives & Ancillary equipment on a world class level in regards of excellent product quality, high productivity and highest logistic performance.

Develop robust, competitive product families for the global market with core competence for high IP rated products.

Highly qualified engineering and qualification services for material, processes (incl. Design for Manufacture & Design for Test) and equipment.

Design, programming, manufacturing and documentation of function test equipment for Inverters, Options and HMI.

Professional project management supported by excellent PLM and NPI processes

Third tier Customer Support using the advantage of local production and R&D facilities.

Repair Centre offering NPI dynamic feedback and customer special investigations.

1971-2011 Manufacturing as a % of GDP - UK

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

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Year

% o

f G

VA

Congleton sales 2002-11

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11

Year

Units

Our Vision

Our Strategic Themes

The key is constant productivity through innovation

DTCContinuousImprovementProcess

LEANIn theOffice

BusinessImprovementProjects

SuggestionsSix Sigma

Increasing Effort / Complexity for Implementation

2 EngineersBudgeted this FY227 Project ideas identified during R&D / Supplier workshop6-12 Months to ImplementPLM Process

1 Part Time Black Belt on loan (GWE)10 Green Belts (Part Time)10 Projects Identified this FY6-12 Months to ImplementDMAIC

3 Full Time HeadsCurrently 8 Part Time Teams and more planned FY1269 Projects under evaluation this FY6-18 Months to ImplementPM@Siemens

0.5 Full Time headCurrently 11 Part Time Teams Meeting Monthly105 Ideas Generated YTD3-6 Months to ImplementPDCA approach

0.5 Full Time headCurrently 15 Part Time Teams Meeting fortnightly294 Ideas Generated YTD3-6 Months to ImplementPDCA approach

0.5 Full Time headCurrently 290 Participants (70% of CNG)1,313 Ideas Generated YTD<3 Months to ImplementSimple Ideas

LEAN CellDesign

0.5 Full Time headCurrently 4 Projects Completed or Ongoing 43 Ideas Generated YTD4 Months to Implement4 Stage Prototype

Outputs from the Productivity Funnel

DTCContinuousImprovementProcess

LEANIn theOffice

BusinessImprovementProjects

SuggestionsSix Sigma

6 Projects started this FY>£100K Potential Identified YTD

8 Projects started this FY>£450K Potential Identified YTD

56 Ideas Implemented YTDAve Saving £5,336 per Team YTD

142 Ideas Implemented YTDAve Saving £6,194 per Team YTD

777 Ideas Implemented YTDAverage Saving £478.98 per Idea

YTD £161K Target £406K



YTD £0 Target £350K



* (YTD = End April 2011), including all productivity measures VAM, CRI & Cost avoidance. Excludes £430K roll over

Good Example.Designed new improved cover with less labelling and improved PCB together with new software and keypad with significant quality improvements Savings £42000/Yr

Good Example.A CIP team identified that one operator can now operates two PCB test systems at the same time instead of one system each.Saving £183,243/Yr

Good Example.A Material Handling LIO team identified that a saving could be achieved when ordering batches of 10,000 pieces instead of 1000 piece.Saving £29,412/Yr

Good Example.A third party supplier was used to customise our G110 drives for UK customer. By setting parameters inline we have eliminated the need for the third party.Saving £9,693/Yr

Good Example.An alarm to alert operators when pallet gets stuck at oven entrance, so that they can solve the problem rather than letting the pallets build up to a backlog situation.Saving £12,107/Yr

Good Example.Skiip’s are damaged upon power up if excess paste is applied during printing. 6 Sigma methods used to identify and reduce scrap.Saving £11,335/Yr

LEAN CellDesign

20 Ideas Implemented YTDAve Saving £6,750 per LCD Idea YTD


Good Example.VS2 LCD team on G110D production line have achieved reduction in floor space by 50% together with process improvements and WIP reduction Saving £81,944/Yr

34 Projects followed throughAve Saving £4,735 per Project

HigherEducation

SchoolEducation

Inte

rmed

iate

•Real skills shortage at technician level. Manufacturing will need at least additional 587,000 new workers over next 10 years mainly technicians

•Apprentice and technician route seen as second- class alternative to University

•40% of Engineering workforce aged > 45

•300,000 UK Graduates / year – only 10,000 engineering (China produces 600,000 engineering graduates)

•30% Engineering Graduates take careers outside of engineering

•Graduates often don’t have the right skills

•Poor perception of engineering and manufacturing•Too few student taking STEM subjects•Low skills and aspirationsNumber of 16 -24 year olds will drop by 8% in next 10 years

The UK Skill’s squeeze and challenge

National engagement Key Programmes

HigherEducation

SchoolEducation

Inte

rmed

iate

Gov

ernm

ent &

Min

ister

ial A

dvis

ory

Gro

ups

Man

ufac

turin

g In

sigh

t/Fu

ture

s

Sect

or S

kills

Cou

ncils

- Se

mta

Asso

ciati

ons

– CB

I / E

EF/R

oyal

aca

dem

y of

Eng

.

Prof

essi

onal

bod

ies

– IE

T/IM

echE

Educ

ation

al –

STE

MN

ET /

Engi

neer

ing

UK

E3 & Power Academy

Lincoln University

Diplomas/Apprenticeships

PM@Siemens Academy

Commercial Academy

Wind Power Maintenance

Schools & Ambassador pr.

LEAs and local agencies

Work placements

Diversity eg WISE

Individual Universities

Programmes; Big Bang etc.

Siemens approach to address ‘the squeeze’

Key Programmes

Primary

Enthuse

Secondary & 6th Form

Enlighten

Secondary & 6th Form(Colleges)Encourage & Engage

Undergraduate sponsorship

Engage

Apprenticeship

Engage

Graduate Recruitment

Engage

Workstream 1 Education / Schools

Workstream 2 Graduates

Workstream 3 Apprentices

1

2

Availability

Attraction and Recruitment

Make It

City

With Partner

Integrated in local business strategy

Sustainable

Employee Engagement

NGOCustomer

Others

Uses Siemens technology

Qualitative KPIsQuantitative KPIs

What

Who

How

Make It helps young people discover what manufacturing means and how it could lead to a rewarding and exciting career in the future

In our first Make It day 120 children from 10 local schools took part They are set challenges to 3 different problems and choose 1 to work on We provide the facilities and hospitability

Partnership with The Manufacturing Institute 6 Siemens managers acting as ‘Dragons’ Apprentices and graduates help the children on the day as ‘consultants’

Result98% of children felt it gave them a better understanding of the careers available in Manufacturing. In addition at the outset 52% said they would consider a career in Manufacturing at the end 82% said they would.

Girls can do it too!

City

With Partner


Sustainable

Employee Engagement

NGOCustomer

Others



What

Where

How

Siemens Motion Control in Congleton are encouraging girls and young women into engineering careers.

Events aim to increase the number of girls taking up engineering diplomas, apprenticeships and careers. Siemens has developed a program of factory tours, talks, events and competitions.

Primary and secondary schools with Siemens (plus other businesses) are working together in establishing a long term transferable model for the learning and skills sector.

Greenpower

City

With Partner


Sustainable

Employee Engagement

NGOCustomer

Others



What

Who

How

Greenpower is working with schools across the UK to encourage students to build and race their cars at motor racing circuits. Each race lasts for 4 hours so reliability, energy efficiency and innovation are key.

Around 600 schools and 10,000 students across the UK are taking part Targeting schools close to Siemens sites to increase participation Provide PLM software to all the schools participating

50 Siemens volunteers support the Greenpower events acting as stewards and marshals Apprentices and graduates help schools with the building of cars

Result Greenpower is monitoring the take up and success of students taking physics, maths and sciences to judge how effective the programme is improving student performance

Big Bang

City

With Partner


Sustainable

Employee Engagement

NGOCustomer

Others



What

Who

How

The Big Bang is the UK’s biggest single celebration of science and engineering for young people. Attracting over 23,000 students over three days from schools around the UK.

Siemens 4d ultrasound scanner on a phantom baby.Build a wind turbine model in actionPractical e-car building with Greenpower

20 Siemens graduates, apprentices and other employees volunteered to man the event for three days

ResultOver 58% of secondary pupils indicated that they were more likely to choose a STEM qualification.Siemens booth was voted in the top 10 attractions

The Urban Sustainablility Centre - London

Apprentices - Siemens plc works with national partners

Siemens Energy example• Siemens took apprenticeship

training in-house in 2008

To guarantee the quality of training provision to meet Siemens plc requirements

• Developed new Apprenticeship Framework for Wind Power Service Technicians

The E3 Academy

• Formed in March 2008 the E3 Academy offers three or four year sponsorship to undergraduate students studying Electrical (Energy) Engineering at the Universities of Nottingham, Bristol or Newcastle.

• This wide and exciting area covers Energy Conversion, Power Electronics, Machines and Generators, Electrical Drives and Control Engineering. This is a huge growth area with applications covering Aerospace, Automotive, Marine, Industrial Manufacturing, Renewable Energies, and Process and Utility Industries.

• Sponsorship is provided by UK-based international companies and the Academy is endorsed by the Institution of Engineering and Technology

• Academy Scholars will benefit from:• a bursary of £2,500 for each year of study. • 8 weeks summer vacation training paid at a rate of £1250 per month. • Academy events, such as the Summer School, where they will meet become acquainted with the Electrical Energy Engineering community. • If subsequently they are recruited by Siemens we pay them £6,000 back for tuition fees

Siemens Commercial Academy

• Alternative career to going to University – 3 Year programme with University day release (BA programme)

• Entry requirements:• B Grades (or above) in GCSE Maths & English• At least 240 UCAS points at A-Level (or equivalent) ideally in Maths,

Business Studies or Economics

Placements in different Siemens operating businesses• Accounting & Controlling• Supply Chain Management• Human Resources• Corporate HQ• Shared Services

• Key Focus areas

•

Move from reactive recruitment to proactive Increased use of academies, internships & sponsorship schemes (e.g. Power & E3 Academy). Recruit increasing proportion of our graduates through this approach – target 70% in 3 years Use local deliver centres/agencies to multiply our engagement e.g. Science Museums Develop better accreditation & development schemes (IET etc) Central pools of mobile Graduates Improved & targeted Branding & communications to Generation Y Fewer but closer Strategic University relationships and engagement

Graduate Activities

1

1 Generation Y – target group born in the 1980s & 1990s, see appendix for summary

Future Provision of Product & Graduate Training

A strategic initiative between Siemens and University of Lincoln

The first new purpose built engineering school in the UK for over 20 years

Commercial contracts and lease

agreements signed Steering groups formed Key staff appointments made Loughborough University

Mentoring

Planning application submitted April

2010 Links to Siemens Asia and NW Europe

made Awarded most “Responsible” project

within Siemens UK

World Class Facility - Lincoln

Over £7M of funding has been allocated to the construction of the new School of Engineering building.

The Hub will combine state of the art R&D ,teaching and training facilities, the building will make an iconic statement about the status and intent of Engineering at the University of Lincoln.

Forming part of the greater campus development, Engineering will take its place in a truly 21st Century University environment.

Key Benefits

Product Training Facility

Research & Development

Industry Ready Students

http://firstnyfcu.files.wordpress.com/2007/08/college-student.jpg

The demand is real!

*And finally……“Making things creates a need for design, infrastructure, production engineering and technological innovation that increases the technical skills base of the nation and creates employment and training opportunities of worth”

“A country of millions of helpdesk operators is not going to set the world alight. Value added to raw materials is more tangible that the parasitical commissions merry go round”

“Arthur Koestler drew an alarming parallel between the Roman Empire, with all the manufacturing processes sub-contracted to the provinces, and the idle, jaded citizens of Rome entertained by vile public spectacles, and the modern world…….and he had not even seen Big Brother or the Jeremy Kyle Show!”

* Taken from a letter to The Times 04/05/2011 Mr Stephen Hart in response to an Opinion piece by David Wighton

And finally……

Proud to be Siemens!

Proud to be a UK Manufacturer!!

Finbarr Dowling MAS2011 Presentation

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