Lean Manufacturing Assistant: Supplier DevelopmentResults: Results:- Reduced lead time by 50% - Reduced defects by 80%- Increased productivity by 30%- Reduced lead time by 60%- Reduced WIP by 70% - Increased OTIF by 95%Client: Client:- Bosch Rexroth AG - Federal Mogul- Germany - USADuration: 2006 - 2010 Duration: 2008 - 2012Contact: Contact: Mr. Thomas Müller Mr. Mike Brown+49 711 811 34 56 +1 248 270 4567mueller@boschrexro
Similar to Lean Manufacturing Assistant: Supplier DevelopmentResults: Results:- Reduced lead time by 50% - Reduced defects by 80%- Increased productivity by 30%- Reduced lead time by 60%- Reduced WIP by 70% - Increased OTIF by 95%Client: Client:- Bosch Rexroth AG - Federal Mogul- Germany - USADuration: 2006 - 2010 Duration: 2008 - 2012Contact: Contact: Mr. Thomas Müller Mr. Mike Brown+49 711 811 34 56 +1 248 270 4567mueller@boschrexro
Similar to Lean Manufacturing Assistant: Supplier DevelopmentResults: Results:- Reduced lead time by 50% - Reduced defects by 80%- Increased productivity by 30%- Reduced lead time by 60%- Reduced WIP by 70% - Increased OTIF by 95%Client: Client:- Bosch Rexroth AG - Federal Mogul- Germany - USADuration: 2006 - 2010 Duration: 2008 - 2012Contact: Contact: Mr. Thomas Müller Mr. Mike Brown+49 711 811 34 56 +1 248 270 4567mueller@boschrexro (20)
Lean Manufacturing Assistant: Supplier DevelopmentResults: Results:- Reduced lead time by 50% - Reduced defects by 80%- Increased productivity by 30%- Reduced lead time by 60%- Reduced WIP by 70% - Increased OTIF by 95%Client: Client:- Bosch Rexroth AG - Federal Mogul- Germany - USADuration: 2006 - 2010 Duration: 2008 - 2012Contact: Contact: Mr. Thomas Müller Mr. Mike Brown+49 711 811 34 56 +1 248 270 4567mueller@boschrexro
5. Overview
• Based on our activities during the last 25 years Wuxi LST combines experiences
from wide variety of industries in Lean Manufacturing, Production
Management and Process Optimization. with extensive process-, technology-
Approach
and practice know-how we are consequently able to advice our clients
throughout the value stream.
• Wuxi LST set the target on providing know-how and support to foreign and
local enterprises to master the challenges the global market and the rapid
changes in China give to them.
Competencies
• The key competencies of Wuxi LST are:
• Lean Manufacturing Training and Implementation,
• Supplier Development,
• Process Optimization and Production Management and Reorganization
Key
6. Overview
• Wuxi LST provided service for local Chinese and foreign
enterprises in the province of Jiangsu and Shanghai.
• Our Lean Experts proved their capabilities throughout their
References
professional carrier.
Entrepreneurial
• Wuxi LST takes entrepreneurial initiative when it identifies
unsatisfied market demands and new business opportunities. In
the second half of 2010 Wuxi LST provided training for foreign
enterprise in the cultural differences between China and foreign
countries. Wuxi LST also provided service in reviewing technical
documents to provide a mutual understanding of the
Spirit
requirements on customer and supplier side.
7. Overview Company Structure & Activities
Wuxi LST Business Consulting and
Service Ltd.
wuxiconsulting wuxirealestate
Lean Manufacturing Real-estate Service
Training Apartment Service
CIP Workshops After Sales Service
Supplier Development Driving License
Process Optimization Language Training
Production Management
8. Management wuxiconsulting
Andreas Brinkmann
GM Business Consulting
Wuxiconsulting
Age: 48
Nationality: German
Phone: +86 151 90 32 85 56
Email: brinkmann@wuxiconsulting.com
Andreas Brinkmann is an graduated Industriemeister Metal IHK & Technischer Betriebwirt IHK . His carrier began in 1982 in the
production of a family owned machine building company in Germany.
In 1992 he took on his first management position in production. From their he took on management positions in different industries
with the responsibility of Implementing Continuous Improvement and Lean Manufacturing to lead the enterprises out of their difficult
situation.
1998 he came to China the first time to train a supplier for his employer, which fast finished after only 5 weeks and resulted in a
prosperous partnership between the Chinese Supplier and the German Customer.
In 2006 he moved to China finally to set-up the first production line of a American automotive supplier and was responsible for the
start-up, staff training and supplier research and development.
In 2010 he decided to provide his knowledge and experience as a Consultant and bought Wuxi LST from its former owner.
10. Business Consulting
More than 25 years of Production and Lean Manufacturing
experience as well as the educational background provide a
Know profound knowledge in the efficient production management
How
The consulting focus is on:
Lean manufacturing training and implementation of CIP.
Focus Strategic and operational development to enable enterprises to
master the challenges of the global market as well of the rapid
development in China
Lean Manufacturing Process Optimization
Supplier Development Process Flow
Topics Production
Management
Kaizen
Continuous
Lean workshops Improvement
11. Work Stream Lean Manufacturing
Value Stream
Strategy Training Implementation CIP
Mapping
• Opportunity • Identify Training • Map the current • Create cross- • Document
Identification needs Value Stream functional improvements
• Assessment of the • Obtain Lean Concept • Develop future Value implementation throughout journey
current state Training Stream teams • Measure, measure,
• Translate Assessment • Define Training plan • Analyze gaps • Obtain specific lean measure – “What
Result into Lean according to client • Create training gets measured gets
Implementation request (Full time / Implementation Plan • Create model area done!”
Strategy Block / Part time) • Conduct KAIZEN • Evaluate support
• Gather baseline Work shops systems alignment
measures • Roll out through the • Never stop
• Identify high impact organization
areas
• Definition of Targets
with the client
12. Work Stream Supplier Development
Supplier liaison
Strategy Development Validation
& support
• Opportunity Identification • Identify Process • Formulating technical • Monitor achieved results
• Assessment of the current Conformity at Supplier recommendations for • Analyze performance
state • Confirm Request carrying out necessary results
• Translate Assessment Awareness at supplier adjustments • Assessment of adjusted
Result into SD Strategy • Analyzing supplier ability • Training supplier processes
• Gather baseline measures to meet main contractors’ • Adjust supplier processes
• Identify high impact areas requirements
• Definition of Targets with • Identify gaps
the client
13. Work Stream Process Optimization
Process
Improvement
Strategy /Organization Validation
Implementation
Assessment
• Opportunity Identification • Identify Process • Train management, staff • Confirm KPI’s according to
• Assessment of the current • Analyze Process Flow and operator Target Definition
state • Analyze Material Flow • Transform current state to • Monthly Assessment
• Gather baseline measures • Analyze Layout future state • Validate adjustments
• Identify high impact areas • Identify improvement • Implement/Monitor KPI’s carried out on a
• Definition of Targets with opportunities middle/long-term base
the client • Design future Flow &
Layout
15. Service - Solutions
Wuxi LST advises its customers in all their
challenges regarding the evaluation and The focus is on the Lean Manufacturing
implementation of Lean and Production optimization of client Process Optimization
Solutions
The solutions team combines deep Lean
processes in order to cut
and Production know how with long costs and secure Production Management
experience in a wide range of
manufacturing industries. competitive advantages. Supplier Development
17. References
Machine Building Metal Precision Automotive
Parts (Piston Ring Plant)
Purpose: Purpose: Purpose:
Optimize Delivery Increase Productivity Profitable Operation
Situation
Result: Result: Result:
60% WIP reduction 20% Increase of 15% Productivity Increase
Delivery time reduction Productivity 60% WIP Reduction
from 6 weeks to 3 days Pass Rate Increase 82% to
98%
Tools: Tools: Tools:
Process Flow Analyze Quick Change Over Plant Layout Restructuring
Standardized Work
& Restructuring Standardized Work Work Instruction
Product Analyze & Work Instruction SixSigma
Creation of Product Poka Yoke
Families Kanban
Continuous Process
Layout Redesign Improvement
KPI
18. References
Automotive Marine
(Heat Exchanger Plant)
Purpose: Purpose:
Setup the 1st production In time delivery
line in China Pass Rate increase
5S and Safety
Result: Result:
PPAP 4 weeks after arrival JIT delivery
in China Pass Rate increase of 5%
Pass Rate 98% in China 5S and Safety Award 2009
(92% in Europe)
Tools: Tools: Project Management
Plant Layout Design 6S Team Work
Standardized Work Takt Time Leadership
Work Instruction
Critical Path Analysis and TPM
Poka Yoke
Kanban Planning Problem Solving
Continuous Process JIT Techniques
Improvement Standard Work Visual Management
KPI Instructions TPM