MilenaSaenz

SWITCH BOARD FACTORY SIEMENS COLOMBIA ENERGY DISTRIBUTION EDMV-P

AGENDA
Generalities
Current measures of Improvements
Future measures of improvements
Siemens manufacturing

AGENDA

1. GENERALITIES Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

The SwitchBoard Factory belongs to Siemens Energy Distribution SA. Located in Bogota, Colombia. It is the unit responsible for the design, mechanical manufacture, integration, assembly and testing of electrical board for applications in different electrotechnology areas.
It develops solutions for various sector of the regording energy distribution, ensuring the highest productivity, quality and efficiency in our production line.
1. ¿Whath is the Factory ? Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

STEEL SHEET COOPER RESOURCES
Siemens machine
Outsourcing Suppliers
Row Material
Siemens and tools personnel
Electrical Equipments
ELECTRICAL EQUIPMENT Outsourcing Suppliers TECHNICAL TESTINGS PRE WIRING Siemens personals and tools 1.2 How does factory do? Processes PUNCHING BENDING WELDING PUNCHING SURFACE TREATMENTS MECHANICAL ASSEMBLY ASSEMBLY AND WIRING BOARDS MANUFACTURE WIRING

PLANIFICACION PREFABRICACION MECANICA MICHAEL VETTER DESARROLLO DE PEDIDOS JAVIER PATIÑO O. RODRÍGUEZ COORDINADOR HUMBERTO GÓMEZ MIGUEL SÁNCHEZ PABLO RIFALDO INDUSTRY ENERGY - M HERNANDO ROMERO COORDINADOR ISRAEL ZABALA PEDRO IBAÑEZ EDWIN FIRACATIVE JULIÁN TORRES COORDINADOR ÓSCAR DÍAZ ENERGY - EA ENERGY – TP/TD HANS MUTTER J. CUBILLOS OMAR SOMBREDERO CONTROL DE CALIDAD Y MEDIO AMBIENTE GESTION DE CALIDAD LUIS VARGAS COMPRAS WILLIAN DE LOS RIOS DISPONENTE MARTHA COGUE JACKELINE HERNANDEZ JEFE DE PRODUCCIÓN ALEXANDER SANDOVAL CAMPO NDE PRUEBAS JOSE SANCHEZ MARTHA RODRIGUEZ NELSON CASTAÑEDA JUAN MURILLO 1.3 Administrative Personnel- Organizational Chart GIOVANNI VALDELAMAR JEFE COMERCIAL PTD-W WILSON VEGA GERENTE FÁBRICA PTD-W RÓMULO HERNÁNDEZ MILENA SÁENZ COMERCIAL JUNIOR LIGIA SÁNCHEZ ASISTENTE ADMIN. PLANEACIÓN ANDREA RODRIGUEZ PLANEACIÓN CARLOS D. MAHECHA JHIMY TRUJILLO COMPRAS

1.3 Administrative Personnel- Organizational Chart

1.4 Reported Data Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

+56% Budget 5.227 1.4.1 Invoices and quantities of the SwitchBoard factory 2005-2012 Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

1.4.2 Our Costumers Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 1.4.3 Behavior of Medium Voltage

1.4.4 Records NC Of´ 2007 vs 2008 Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 Supplier NC Disign NC Factory Nc standardization NC

Q NC-s Additional 2,74* 0,67* *Number of NC’s per person 2007 2008 2007 2008 13% 1.4.4 Records NC Of¨ 2007 vs 2008 Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

2. CURRENT MEASURES OF IMPROVEMENTS Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

With the standardization of our products and processes, the factory created a brochure for our clients. 2.1 Standardization Processes Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

STRATEGIC ALLIANCES We have generated strong bonds with our suppliers, this way our production is more flexible and adaptable to the changes of the market. We search in our constumers high standards of quality, like internal programs of continuous imrprovement to guarantee excellence in our production . 2.2 Outsorcing / Strategic Alliance Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

2.2.1 Methalmecanics

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 PINTECO Fimm power c5 Until Cr 6 Bending machine Adira 225 Ton Punching Machine CNC 2.2.1 Methalmecanics

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 Industrias Pintumel 2.2.1 Methalmecanics

SILVER SURFACE TREATMENT BICROMATIZED PAINTING 2.2.2 Superficial Treatments Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

INSULATOR PLATES ACRYLICS MECHANIZED 2.2.3 Other processes

2.2.4 Cost Savings Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008
Avoid inflammable liquids manipulation
Staff Reduction Costs
Maintenace reduction
Wiring Productive area 324 mts2
** ** 39.9% 42000 7000 INSULATOR PLATES 10% METAL- MECHANICS 84% 67.423 124.286 SILVER SURFACE TREATAMENTS 8% 238.154 260.514 PAITING SAVING % AFTER BEFORE PROCESSES COST ( Euros)

Waste Reduction Noise Reduction Professional Risk Reduction Less danger Less Costs ENVIRONMENTAL IMPACT Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 2.2.5 Benefits Outsourcing Processes

Reduction in Maintenance Costs
Optimization of the working area
Improvements in industrial safety.
Production has increased in 57% due to our external processes
2.2.5 Benefits Outsourcing Processes Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

2.3 Inventory Mangament , Measure

Causes
• Defficient structure of inventory.
• Deficient usage of our resources.
• Insufficient infrastructure capacity (Storage)
• Inadequate Plan of supply period
• Non- flexible Production Plan
• Non- standardization Products
2.3.1 Causes Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

Movement of inventory costs to costumer It was detected that it was not possible to invoice many production orders given that the electrical equipments of the panels had not arrived to the factory , hence is was not possible to deliver them to the client ; ( the client is the part responsible of the ensuring the on – time arrival of the equipments) .As a result the factory decided to make agreements to anticipate invoices . This way the working processes will be reduced . To list updated production orders. To order chronologically the reasons of the delay To Identify the cause of delay with quality To Talk with the client to get agreements with the movements costs. To check with the warehouse the material delivery. To invoice the pending orders 2.3.2 Current Activities Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

Optimazation of the structure of the provisioning material The structures are overvalued in quantities and also a lot material exist with low rotation and hight scope that actually is not being used in production. The factory will be identified this material to sale and reduce the own material. The purchase processes will be aligned with the process Source SCM , assignig the roles and responsasbilities clear To make a report of all material ( Provisioning risk quantity) To analize the risk quantity and Thecnical and identify the materials with a scope major a 18 months To identify the material that can be used in currents proyects To Detain order purchase with similar material To identify suppliers that can be interesting to buy material To sell material obsolete To revaluate the wayy thas was being calculated To Define clear rsponsabilities of the approvisioning process To adjust the structures of finished products 2.3.2 Current Activities Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 2.3.2 Current Activities

2.3.3 Scope Inventory Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 Months

Movements of inventory costs to constumers Optimization structure of the provisioning material BNK = COP 24,1 mill / mes = COP 163,3 mill Recovery for sales material = COP 173,1 mill Responsabilities clear = COP 30,5 mill Total = COP 367 mill = US 200.000 2.3.4 Cost Savings Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

2. 4 5´S Program

Classify, organize and clean.
Create a new roll about The Production Leader with specific responsibilities
Restorage of non used of row material per work station
2.4.1 Implementation of 5´S Program Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

After Before 2.4.1 Implementation of 5´S Program Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

2. 5 Latest Products

2.5.1 Latest Products SIMOPRIME

8PT
Protection Grade IP30 to IP54
ICW Until 150 KA
IN Until 7400 A
Internal separation with 60439 Term
BENEFITS
Reduction in disign Time
Estructures with TTA / PTTA Certificates
Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 2.5.2 Latest Products

2.5.3 . Software, Trainnig and Quality Certificates Quality Certificate Training Certificate Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 2.5.3 . Software, Trainnig and Quality Certificates

2. 6 Lean Manufacturing

The factory made a pilot test in the circuit breakers assembly area. The production flow was analized and improved. 2.6.1 Circuit Breakers Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 Circuit Breakers

BEFORE AFTER Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 2.6.1 Circuit Breakers

BEFORE
Activities
Rails , Wiring Ducts and cables cutting
Mounting of accesories and contact terminal
Medium Voltage Harting Wiring
Printing a Labels area was created for a better efficient production
Non Productive area
AFTER 2.6.2 Pre wering Work Station – Pre Wiring

Render Priview Current 2.6.2 Pre wering Working Station – Pre Wiring Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008

3.1 Planning Software & Production Input Type Of Product Quantity Date of Delivery Data Base Standardized Products Master of Materials TAROK-SAP Factory Resources Daily Updates OutPut Order Factory Capacity The optimun use of resources Occupation by working Place Row Material by working place Reports and statistics Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 Order Delivery Program SPCP

Reduction in deliveries.
Production in series.
Waste Reduction
Reduction of station, 7 to 3
3.2.1 Copper Machine Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 43.307 euros 961% 188 euros ANUAL SAVING % DAILY SAVING DAILY SAVING

3.2.3 Cable Machine Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008
Major Efficient in our processes.
3000n mts / Hour
The Consumption of cable will be increased in 432%

4. Siemens Manufacturing

4.1 Overview- Benefits Current Factory vs Siemens Manufacturing Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 50% Reduction 120 millones COP 240 millones COP 34% 13.20 9.8 Over Time Cost -32,% 100 147 Indirect Employess 86% 130 70 Direct Employees 105% increase 4000 m2 1950 m2 Area M2 Increase % Siemens Manufacturing Currenttly Parameter

Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 4.4 Testing Of Panels and Circuit Breakers and Bushing Comparments

4.6 Low Voltage Assembly

PRUEBAS SIEMENS MANUFACTURING Nov. 2008 Energy Distribution © Siemens Austral – Andina 2008 4.12 Protection & Control Test Field

MilenaSaenz

by milena10 on Nov 23, 2008

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