Corporate Profile 47Billion Information Technology
Manufacturing excellence
1. To bring our industrial operations to World Class Level Introduction To Manufacturing Excellence Presented by YS Lin E-mail: [email_address] Mobile: +886-936883828 2010-10-16
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5. - ZERO DEFECT - 6 SIGMA - RELIABILITY - CUSTOMER COMPLAINT - ISO9000 ETC. - SERVICE - DELIVERY - QUICK RESPONSE TIME - SHORT ORDER LEAD TIME - RUSH ORDER HANDLING - FLEXIBILITY OF ORDER CHANGE MANUFACTURING EXCELLENCE HUMAN RESOURCES - LABOR SHORTAGE - VALUE COMPETITION - NUMBER OF COMPETITORS - IMPRROVEMENT SPEED FROM COMPETITORS PRODUCT DEVELOPMENT - DIVERSITY - FEATURES COST - ENVIRONMENTAL COST - WAGE INCREASE - EXCHANGE RATE - INTEREST - MATERIAL PRICE ENVIRONMENT - PROTECTION - WASTE ELIMINATION - RECYCLING CYCLE TIME - TIME TO MARKET - LEAD TIME (ORDER, COMPLAINT HANDLING) - TPT THE CHALLENGES TO CORPORATE EXCELLENCE QUALITY FLEXIBILITY
6. NEW PARADIGM OF MANUFACTURING EMPHASIS ON SPEED AND FLEXIBILITY I.S.O VOLUME AND COST. G4101506 DIMENSION FROM TO 1. PEOPLE SPECIALISED MULTI-SKILLED 2. STAFF NECESSARY,THE OVERHEAD,THE MORE THE BETTER LESS THE BETTER 3. REJECTS ALLOWABLE UNACCEPTABLE 4. COMMUNICATION FORMAL, INFORMAL, HIERARCHICAL HORIZONTAL 5. EQUIPMENT PROCESS UNIVERSAL, SPECIFIED GENERAL PURPOSE 6. GOODS FLOW PROCESS ORIENTED PRODUCT ORIENTED 7. FOCUS LABOR OR EQUIPMENT PRODUCTION UTILIZATION THROUGHPUT TIME 8. INVENTORY BUFFER WASTE, DEVIL 9. SUPPLIER SHORT-TERM LONG-TERM, RELATIONSHIP COOPERATIVE, PARTNERSHIP 10. PRODUCT SEQUENTIAL CONCURRENT, DEVELOPMENT CROSS-FUNCTIONAL ACTIVITY TEAMS BASIC CONCEPT LEAN APPROACH
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8. BUSINESS PLAN - Products - Markets - Financials TECHNOLOGY ROADMAP INDUSTRIAL PLAN - What? - Where? - How?
13. WHERE TO MAKE ? 1. Regionalization of global manufacturing 3 regions : North-America West-Europe Asia-Pacific 2. Copy exactly issue Each region has own “border zone”
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15. CHAIN MANAGEMENT 1. The creative chain = Product Creation Process Needs/ Ideas Product concept Product definition Process definition 2. THE LOGISTICS CHAIN = Manufacturing plus …. Suppliers Manufacturing Distribution Customers
16. From “MANUfacturing” to “MENTOfacturing” MANUfacturing = Made by hand MENTOfacturing = Made by the mind Question : How to exploit the brainpower And the creativity of all our people ?
17. COST OF THE ORGANIZATION Far more savings possible via elimination of unnecessary indirect jobs, than via automation of the last direct jobs
18. Quality Assurance From PRODUCT CONTROL to PROCESS CONTROL BATCH RELEASE PRODUCT RELEASE PROCESS RELEASE ( 6 , Cpk )
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20. Manufacturing Revolution or Evolution? (How much time left ?) Manufacturing Mento-facturing Directs-Indirects Added cost / added value Management information People information Motivation Training & Information Functional departments Process improvement teams
21. How ? INSPECTOR OPERATOR SUPERVISOR FACILITATOR MANAGER COACH ADDED COST ADDED VALUE
25. CUSTOMER - ORIENTED COMPANY ECONOMIC GROWTH PRODUCT-PROCESS DESIGN PRODUCTION CAPACITY INVESTMENT SUPERIOR QUALITY SUPERIOR PRODUCTIVITY SUPERIOR FLEXIBILITY PRODUCTION PLANNING CUSTOMER DESIRES PRODUCT-PROCESS SPECIFICATIONS WORLD-CLASS MANUFACTURING TOTAL CUSTOMER SATISFACTION SUPERIOR PRODUCT, VALUE, AVAILABILITY WORLD-CLASS MANUFACTURING TECHNOLOGIES PEOPLE MATERIAL EQUIPMENT INFORMATION RESEARCH AND EDUCATION CONTINUOUS INVESTMENT AND IMPROVEMENT SOURCE : "REENGINEERING THE FACTORY", A. RICHARD SHORES OBJECTIVE STRATEGY GOAL TACTICS PROCESSES RESOURCES SCIENTIFIC METHODS KNOWLEDGE
26. WORLD CLASS MANUFACTURING TECHNOLOGY WORLD-CLASS MANUFACTURING MANUFACTURING RESOURCES AND PROCESSES POM TQC SMT QFD DFM ATM CIM JIT WORLD-CLASS MANUFACTURING TECHNOLOGIES RESEARCH AND EDUCATION CONTINUOUS IMPROVEMENT (KAIZEN) - KEY : KAIZEN, CONTINUOUS IMPROVEMENT - POM : PROCESS OF MANAGEMENT - TQC : TOTAL QUALITY CONTROL SMT : SELF-MANAGED-TEAMS QFD : QUALITY FUNCTION DEPLOYMENT DFM : DESIGN FOR MANUFACTURING ATM : AUTOMATION CIM : COMPUTER-INTEGRATED MANUFACTURING JIT : JUST-IN-TIME SOURCE : "REENGINEERING THE FACTORY", A. RICHARD SHORES ......
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28. Visual evaluation of a good factory 5. Performance-information on the line per line per workplace Information on . Quality (short loop) . Efficiency (output) 6. Number of indirects on the floor? How many people “hanging-around” for . Supervision? (why?) . Q-problems . Material supply 7. Contact pattern? . Management presence on the floor? . Open offices?
29. Visual evaluation of a good factory 8. Is “production” the heart of the business? Are support departments really supporting? 9. Housekeeping Is the place clinically clean? 10. Working atmosphere? Do we smell the “winning spirit” ? 11. Would you like your son or daughter to work here in the “production” ?
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38. Posting company-wide activities on the wall 3. Improvement activities and performance scoreboard
47. FORMULATION OF MANUFACTURING STRATEGY L.T OBJECTIVE BUSINESS STRATEGY MANUFACTURING STRATEGY CORE COMPETENCE COMPETITIVE ADVANTAGES L.T BUSINESS SUCCESS BUSINESS ENVIRONMENT MANUFACTURING TECHNOLOGY ORGANIZATIONAL CAPABILITY TYPE ELEMENT CHARACTERISTIC EXTRINSIC, MECHANIC INTRINSIC, SUBSTANCE - SKILL & KNOWLEDGE - PHYSICAL SYSTEM - MANAGERIAL SYSTEM - VALUES SELECT PRACTICE TO BUILD DESIRED COMPETENCES - POM (PROCESS OF MANAGEMENT) - TQC (TOTAL QUALITY CONTROL) - SMT (SELF-MANAGED TEAMS) - QFD (QUALITY FUNCTION DEPLOYMENT) - DFM (DESIGN FOR MANUFACTURING) - ATM (AUTOMATION) - CIM (COMPUTER INTEGRATED MANUFACTURING) - JIT (JUST IN TIME)
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49. Training Courses design Generic training, distinguished levels and focus: Level 1 : Shop floor Management (Grade 50/60/70; 5x3 days) Control and improvement Textbook: The New Shop Floor Management Author: Kiyoshi Suzaki The free press- A division of Macmillan, Inc. NY Training material: Period 1-5, Value 20,000 USD Level 2 : Manufacturing management (80/90;10 days in 3 blocks) Defining improvement and renewal, managing implementation and change Level 3 : Industrial management (100/directors; 5 days) Defining manufacturing strategy Determining performance gap Determining opportunity gap Managing implementation and change