Sogefi : Du produit au lean engineering
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Sogefi : Du produit au lean engineering

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David Jacquart et Lionel Verchere présentent la façon dont ils ont démarré le Lean chez SOGEFI AC, en choisissant de démarrer simultanément en Production mais aussi au développement. Découvrez ...

David Jacquart et Lionel Verchere présentent la façon dont ils ont démarré le Lean chez SOGEFI AC, en choisissant de démarrer simultanément en Production mais aussi au développement. Découvrez leur l'expérience, les succès, les apprentissages, mais aussi les difficultés rencontrées.
Retrouvez les événements, master class et la librairie du lean management sur le site de l'Institut Lean France.

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Sogefi : Du produit au lean engineering Sogefi : Du produit au lean engineering Presentation Transcript

  • 11ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering…du Produit au Manufacturing EngineeringParis, 9th April 2013SOGEFI GROUP / Engine System Division / Air & Cooling / Orbey , March 2013Manufacturing Air & cooling Production SystemMAPSDevelopping People First !
  • 22ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering SOGEFI Group MAPS, Historique et principales réalisations Un choix : celui d’embarquer de suite le développement etl’ingénierie Le Lean en Ingénierie : participation aux HOSHIN, « IngénierieCarton », Slow Build, A3 Report, et les quelques décisionsprises comme le découplage et ses conséquences sur l’indus … L’Obeya Projet et Industrialisation Les Targets Cost Event Questions/RéponsesSommaire
  • 33ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering SOGEFI Group MAPS, Historique et principales réalisations Un choix : celui d’embarquer de suite le développement etl’ingénierie Le Lean en Ingénierie : participation aux HOSHIN, « IngénierieCarton », Slow Build, A3 Report, et les quelques décisionsprises comme le découplage et ses conséquences sur l’indus … L’Obeya Projet et Industrialisation Les Targets Cost Event Questions/RéponsesSommaire
  • 44ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringSOGEFISogefi is a world leaderin the design andmanufacturing ofengine filtration,suspension vehicletechnologiesSogefi owns a fully integratedindustrial process – fromengineering to manufacturingto assembly – that guaranteesthe best quality andimprovement of productperformanceInnovation driveseach of Sogefi’score businesses,supported byengineers andtechniciansin 9 R&D centersacross the worldSOGEFI, an Italian group on the Italian Stock Exchange, is a Worldwideleader in the automotive parts industry, specialised in engine systemsand flexible suspensions components since 1980
  • 55ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringSOGEFISOGEFI Group can provide to car manufacturers sub-assemblies and complete modules with high addedvalue in the areas of air intake and coolingAIR INTAKE & COOLING SYSTEMS Headquarter: Orbey, France Manufacturing locations : France, Romania,Canada, Mexico, India, China and Brazil 1200 employees 312 M€ External Revenues in 2011
  • 66ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering SOGEFI Group MAPS, bref historique et principales réalisations Un choix : celui d’embarquer de suite le développement etl’ingénierie Le Lean en Ingénierie : participation aux HOSHIN, « IngénierieCarton », Slow Build, A3 Report, et les quelques décisionsprises comme le découplage et ses conséquences sur l’indus … L’Obeya Projet et Industrialisation Les Targets Cost Event Questions/RéponsesSommaire
  • 77ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringManufacturing Air & cooling Production SystemDevelopping People First !vvvvv
  • 88ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringLean en ProductionLean en Conception des Moyens de ProductionLean en Conception ProduitNotre choix …
  • 99ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous fait depuis 2009 ?2009 Project start upBenchmark and TOP Management trainingTraining Program : 400 employees / 4000 hoursValue Stream Mapping (VSM) in all PlantsVisual management : Parts board on all machinesLean and Supply Chain departments createdJapan Study Tour at Toyota and Sensei2010
  • 1010ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous fait depuis 2009 ?Focus on Employees EmpowermentTeam Leader Organization LaunchingManagement Visuel (Shop stock, Part Boards, Red Bin, …)Kaizen : 1 Hoshin / month / plant5S, Standardized Work, Red Bins, SMED and Kanban as common ToolsPull System : Levelling, Truck Preparation Area / Pool Stocks,Shop stocks are being to be implemented2011
  • 1111ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous fait depuis 2009 ?2011 Product / Process Developpment  Obeya Room- Visual Managment Project- Target Cost managing for major project
  • 1212ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringAvec Quelle Dynamique ?To reach a Lean Level, we have to do :- Improve Customer Satisfaction- Internal Quality … from 60 000 to 10 PPM- Reduce Lead Time … to increase our Cash- Standardized Work, to do all on right time …… , for Production and Developpment
  • 1313ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringAvec Quelle Dynamique ?To ImproveEngineering« simulation »Pull FlowHOSHINLet’s move the company !- Customer Satisfaction- Our JIT Conditions- Our JIDOKA- Our Standardized WorkThe leader is the Plant …… because Added Value is created by the Plant !Co-ConceptionProduct/ProcessTarget CostManagementHOSHIN
  • 1414ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous appris ?A HOSHIN Plan for all PlantsThis is the Key for our Lean Plan :- Training to production team (Supervisors and Team Leader)to reset our production cells : Improve Operators Work Conditions Takt Time for each production cell Improve Internal Quality on the shop floor (internal ppm) Operators empowerment with Standardized Work
  • 1515ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous appris ?100 HOSHIN :- 1500 Ergonomy issues fixed- Internal Quality : - 50% Internal ppm- Lead time decrease : - 20% / year- Standardized Work done with Operators- Direct Labor Efficiency Improvment : + 20%- A real « Flight simulator » for Engineering Dpt who participe ateach Workshop
  • 1616ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 1717ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 1818ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous appris ?A “Flight Simulator” for Engineering … The HOSHIN workshop done before launch- Material and Information Flow Analysis and A3 report / project- Data base for Time standard (MTM2) and Standardized Machine- Standardized work for each new Production line, Slow Build and “Ingénierie Carton”- Standardized Work at Engineering Dpt (Technicals Meeting each Friday, …) Improve Customer Satisfaction (Production) Improve internal Quality (capability machine) CAPEX Reduction (more flexibility) Reduce the Engineering Lead Time Technical Expertise Improvment
  • 1919ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringENSEMBLEOUTILSPRODUCTIONCONCEPTION PROCESS« METHODES »Apprentissage … Le métier• Participation aux chantiers HoshinCapitalisation des bonnes pratiques et les intégrer dans l’ingénierie des nouveaux produits• Amélioration de l’Ergonomie des postes de travail et validation avec CAP TMS• Industrialisation CartonMaquetter avec les opérateurs pour optimiser les flux et l’ergonomie.• Slow Build (avec des fournisseurs de moyens)Analyser les opérations d’assemblage pour les optimiser
  • 2020ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringApprentissage … Le métier• Target CostParticipation aux Event pour optimiser le coût total du produit, et consolider la marge• Plan d’innovation : pour séparer l’innovation des développements• Set-based : Etude de toutes les solutions pour ne pas prendre des décisions trop tôt qui créentdes surcoûts.• A3 d’industrialisation : Etablir la communication avec l’usine et challenger les équipes avec desobjectifs communs.• Travail standardisé : Définir le guide d’utilisation du process pour le manager de production• Machine standards : standardiser pour diminuer les CAPEX et intégrer les besoins de laproduction
  • 2121ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringApprentissage … Le métier
  • 2222ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringApprentissage … Le métier
  • 2323ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 2424ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 2525ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 2626ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 2727ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 2828ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous appris ?Improve the Product/Process Co-Conception to reach Targets CostOBEYA Room created :- Visual Management for major projects- Target Cost Management- Understand the Real production problems- Research and Development Standardized Work
  • 2929ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineering
  • 3030ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing EngineeringQu’avons-nous appris ?Improve the Product/Process Co-Conception to reach Targets Cost Improve the Customer Satisfaction and developing our business Reach Targets Cost Improve Quality Reduce the R&D Lead time Improve our Technical and “know how” Expertise
  • 3131ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFIs prior written approval.Du Produit au Manufacturing Engineeringwww.sogefi.itTHANK YOUFOR YOUR ATTENTION