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© 2013 Datameer, Inc. All rights reserved.
View Full Recording
You can view the full recording of this webinar at:
http://info.datameer.com/Online-Slideshare-LeanPro...
About our Speaker
Conny von Ludwig
Conny von Ludwig is Manager of Continuous Improvement
Process at a large car manufactur...
About our Speaker
Conny von Ludwig
Conny von Ludwig is Manager of Continuous Improvement
Process at a large car manufactur...
About our Speaker
Stefan Groschupf
Stefan Groschupf is the co-founder and CEO of Datameer.
He is one of the original contr...
Lean and Flexible Enterprises
Corporate
strategy
Effectiveness
Division / product strategy
Suppliers

Customers

Doing the...
Why Lean Production
Increase:
Productivity
Customer Satisfaction

Ability to:
Deliver Just-in-Time
Produce customized prod...
The “Lean Production”
Philosophy
“Perfection has been reached, when nothing can be taken away, not when nothing
can be add...
How Waste Can be Identified
Process

Product

Redundancy
Inventory
Bottlenecks
Numerous interfaces
Work flow disruption
Inco...
Principles More Important
than Methods
Synchronization

Value Orientation
Objectively measurable
Value from customer’s per...
Vision of Just-in-Time, 5R

Information

Material

Part

Part
Time
Right

Quality

+

Time
Right

Quality

Place

Place

Q...
Overall Processes
Raw material
Machines
People
Information

Input

Good
Information

Process

Use information from process...
Value Stream Material &
Information Flow
PPS

Order

Information
flow

Shipping order
Customer

Supplier

Process

Material...
Value stream with Material- and Information
flow
Information
flow

Material
flow

Focus of improvements today

Info

Informat...
Improvement Process:
8 Success Factors
Willingness
to change

CIP organization

Methods/tools

Training

Process Vision

W...
Factors of a Lean Shop
Foreman
Quality assurance

Work / shift

Relieved of all duties
throughout the workshop
CIP Trainer...
Improving Processes with Big Data
Good Results
Competitive organizations provide
lower product costs, increased quality & ...
Improvement Processes
Define

Define the opportunity
Understand process and performance

Measure
Analyze
Improve
Control

Se...
Summary
Big Data provides new approach for process optimization
Provide easy to use tool to analyze & improve processes
Fo...
Demo

© 2013 Datameer, Inc. All rights reserved.
Lean Production
•

Manufacturing plant

•

Predictive maintenance

•

Minimize downtime
•

Which robots are failing the mo...
Use Case
•

Correlate sensor data from multiple sources

• Maintenance ticketing databases
• Machinery log files

© 2013 D...
Total Operating Time
No scheduled for
production

A

Available time

B

Measure

C

Theoretical production

D

Real produc...
@Datameer
Resources

http://www.datameer.com/learn/index.html
Follow us on Twitter @Datameer

© 2013 Datameer, Inc. All rights reser...
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Lean Production Meets Big Data: A Next Generation Use Case

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Watch this recording at: http://info.datameer.com/Online-Slideshare-Lean-Production-Meets-Big-Data.html

Sensor and robotic data will usher in a new wave of big data opportunities and use cases in 2014.

This will be especially true in manufacturing as economic pressure to continuously improve operational efficiencies continue to challenge the bottom line.

Join Lean Production Expert Conny von Ludwig (former Porsche Consulting & Lufthansa), and Datameer CEO, Stefan Groschupf as they discuss:

-the current manufacturing challenges and how big data analytics can improve these inefficiencies
-how to reduce production outages by 10%
-a next gen big data analytic use case focused on manufacturing sensor data

Published in: Technology, Business
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Transcript of "Lean Production Meets Big Data: A Next Generation Use Case"

  1. 1. © 2013 Datameer, Inc. All rights reserved.
  2. 2. View Full Recording You can view the full recording of this webinar at: http://info.datameer.com/Online-Slideshare-LeanProduction-Meets-Big-Data.html © 2013 Datameer, Inc. All rights reserved.
  3. 3. About our Speaker Conny von Ludwig Conny von Ludwig is Manager of Continuous Improvement Process at a large car manufacturer in Germany.  He has been in charge of planning and implementing internal projects focused around lean processes at various production plants in Germany.  Prior to this, he was a Lean and Training specialist at Porsche Consulting and Lufthansa Technik.  He has more than 15 years of practical lean production and lean thinking know-how in several industries around the world. © 2013 Datameer, Inc. All rights reserved.
  4. 4. About our Speaker Conny von Ludwig Conny von Ludwig is Manager of Continuous Improvement Process at a large car manufacturer in Germany.  He has been in charge of planning and implementing internal projects focused around lean processes at various production plants in Germany.  Prior to this, he was a Lean and Training specialist at Porsche Consulting and Lufthansa Technik.  He has more than 15 years of practical lean production and lean thinking know-how in several industries around the world. © 2013 Datameer, Inc. All rights reserved.
  5. 5. About our Speaker Stefan Groschupf Stefan Groschupf is the co-founder and CEO of Datameer. He is one of the original contributors to Nutch, the open source predecessor of Hadoop, Stefan has been at the forefront of the Hadoop and Big Data market. Prior to Datameer, Stefan was the co-founder and CEO of Scale Unlimited, which implemented custom Hadoop analytic solutions for HP, Sun, Deutsche Telekom, Nokia and others. Earlier, Stefan was CEO of 101Tec, a supplier of Hadoop and Nutch-based search and text classification software to industry-leading companies such as Apple, DHL and EMI Music. Stefan has also served as CTO at multiple companies, including Sproose, a social search engine company. © 2013 Datameer, Inc. All rights reserved.
  6. 6. Lean and Flexible Enterprises Corporate strategy Effectiveness Division / product strategy Suppliers Customers Doing the right things Functional area strategy Development strategy Purchasing strategy Production strategy Sales strategy Organization Efficiency Processes Management process Development Purchasing Production Supporting processes Products © 2013 Datameer, Inc. All rights reserved. Sales Doing things right
  7. 7. Why Lean Production Increase: Productivity Customer Satisfaction Ability to: Deliver Just-in-Time Produce customized products Lean production is the enabler for profitable and sustainable growth © 2013 Datameer, Inc. All rights reserved.
  8. 8. The “Lean Production” Philosophy “Perfection has been reached, when nothing can be taken away, not when nothing can be added.” - Antoine de Saint Exupéry Customer satisfaction Quality Cost 5% of activities create value Types of waste Overproduction Transportation Wait times Rework/defects Transit time Inventory Over processing Delivery Service © 2013 Datameer, Inc. All rights reserved.
  9. 9. How Waste Can be Identified Process Product Redundancy Inventory Bottlenecks Numerous interfaces Work flow disruption Inconsistent documents Duplicate handling Exceed performance requirements Unnecessary range of functions Volume of unused variants © 2013 Datameer, Inc. All rights reserved. Organization Complex structures Unclear responsibility Wasted employee capabilities Wrong employee attitude
  10. 10. Principles More Important than Methods Synchronization Value Orientation Objectively measurable Value from customer’s perspective Waste is avoided Think in processes, not departments Processes are linked Supply and demand are aligned Core Elements of Lean Enterprise Measurable objectives and results Top-down target setting Bottom-up problem solving Transparency © 2013 Datameer, Inc. All rights reserved. Standards facilitate improvement Pursuit of perfection Always question achievements Perfection
  11. 11. Vision of Just-in-Time, 5R Information Material Part Part Time Right Quality + Time Right Quality Place Place Quantity Quantity © 2013 Datameer, Inc. All rights reserved.
  12. 12. Overall Processes Raw material Machines People Information Input Good Information Process Use information from process for improvements © 2013 Datameer, Inc. All rights reserved. Output
  13. 13. Value Stream Material & Information Flow PPS Order Information flow Shipping order Customer Supplier Process Material flow Focus of improvements today Info Process Process Info Shipping Info Process Info Information replace waste (e.g. inventory) © 2013 Datameer, Inc. All rights reserved. Process information data: Logistic Quality Maintenance Personnel Production planning Process performance Lean indicator: Throughput time
  14. 14. Value stream with Material- and Information flow Information flow Material flow Focus of improvements today Info Information replace waste (e.g. inventory) © 2013 Datameer, Inc. All rights reserved. Info Info Process information data: Logistic Quality Maintenance Personnel Production planning Info Process performance Lean indicator: Throughput time
  15. 15. Improvement Process: 8 Success Factors Willingness to change CIP organization Methods/tools Training Process Vision Workshop/ Project Plan Key Performances Indicator Communications © 2013 Datameer, Inc. All rights reserved.
  16. 16. Factors of a Lean Shop Foreman Quality assurance Work / shift Relieved of all duties throughout the workshop CIP Trainer Engineering/Planning Logistics Union rep CIP Trainer Workshop organization Training of participants Procurement of methods Coordination of stabilization © 2013 Datameer, Inc. All rights reserved. Participants Idea generation Improve concept development Measure implementation Knowledge contribution Presentation
  17. 17. Improving Processes with Big Data Good Results Competitive organizations provide lower product costs, increased quality & profits ✔︀︁︂︃︄︅︆︇︈︉︊︋︌︍︎️ Good Processes These results must be directly & indirectly optimized (sustained) for improvement Ac Good Employees Employee competency will implement these plans successfully © 2013 Datameer, Inc. All rights reserved. t Pla Ch eck Do n
  18. 18. Improvement Processes Define Define the opportunity Understand process and performance Measure Analyze Improve Control Search for biggest impact factors on process performance and determine root cause Develop improvement solution for the critical X’s Implement the solution and control plan © 2013 Datameer, Inc. All rights reserved.
  19. 19. Summary Big Data provides new approach for process optimization Provide easy to use tool to analyze & improve processes Focus not only on visible wastes but also systems Think through processes with cross-functional analysis Measure results for measurable decisions (important in implementation) Sustainability Datameer is so easy to use that even employees can analyze processes and improve them. © 2013 Datameer, Inc. All rights reserved.
  20. 20. Demo © 2013 Datameer, Inc. All rights reserved.
  21. 21. Lean Production • Manufacturing plant • Predictive maintenance • Minimize downtime • Which robots are failing the most ? • What part of the day do failures most occur ? • What is the average length of time between failures ? © 2013 Datameer, Inc. All rights reserved.
  22. 22. Use Case • Correlate sensor data from multiple sources • Maintenance ticketing databases • Machinery log files © 2013 Datameer, Inc. All rights reserved.
  23. 23. Total Operating Time No scheduled for production A Available time B Measure C Theoretical production D Real production E Real production F Good products Failure Idle Time Minor Stops Speed Loss Scrap Rework OEE = B/A x D/C x F/E Availability Efficiency © 2013 Datameer, Inc. All rights reserved. Quality
  24. 24. @Datameer
  25. 25. Resources http://www.datameer.com/learn/index.html Follow us on Twitter @Datameer © 2013 Datameer, Inc. All rights reserved.
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