1. 09/06/16
Restricted © Siemens plc 2013 All rights reserved.
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Presentation Template v.3.0
TP585-001
Lean Cell Design Project
Arya Dash, Manufacturing Engineer, SIEMENS PLC

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What do we do at Siemens Congleton?
Siemens in Congleton employs 450 employees and is a
 Global supplier of industry-specific drives that control AC Motor speed by
varying the current and frequency.
 The market extends across 190 countries with annual revenue of £74m last
year.
Applications: SKiiP
Heat-sink
Electronics

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Where it all started- Business Need!!
• Old product
• Demand has dropped from ‘21’ to ‘12’units a shift.
• Number of operators in the cell have been reduced from 3 to 1.
• Inefficient layout for ‘One person Build Process’
• Current output is only 7 units a day.
My Job:
 Shrink the size of the cell to make space for a new product
 Upgrade capacity to improve the output with one person working in the cell

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What’s wrong with the current cell: Understanding
the challenges
•Takes up a lot of space!!
Total Area: 110 sq. m
•Excess Motion!!
134 Steps per unit
•Excess Inventory:
•Poor Delivery Performance!!

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How did I address the challenges?
•Initial investigation and experience
•Process Simulation and Calculation
Why?
•Designed smarter storage solutions
(Karakuri Systems)- Reduced floor
space
•Reduced the number of tools- Cost
Avoidance
•Amalgamated work stations- Improved
build times and motion
•Designed slick workstations with quick
change over capabilities- Reduced
Waiting and Downtime
Current State PFA
Data Gathering,
Standard Times etc.

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Cardboard Mock up:
Construct mock up of workstation using cardboard
• Go through the build process and decide the
best place for material / parts
• Bearing in mind storage quantities
• Correct container size
• Placement of tools
• Simulate first production without screwing or
soldering
Duration: approx. 3 days
Cardboard Mock Up- Getting the ‘Buy-in’ Zero Defects &
Continuous Improvement

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New LCD Workstation:
• Order and delivery of the new LCD
Workstation/ESD work tops
• Revise production layout and plan as required
• Reevaluate standard time
• Capture savings
Final Install Zero Defects &
Continuous Improvement

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Achievements
Before Target set
by
Simulation
Achieved
by the
Team
Reduction
in %
Annual Cost
Savings (£)
Floor Space 110 sq. m 55 sq m 47.5 sq.
m
57% 26,040.00
Standard
Time/output
40.2 29.3 26.5 34% £3,500(based
on forecast)
Motion 134 steps
per unit
68 steps
per unit
56 steps
per unit
52% 780.00
Tooling 22 14 14 36% 8,000.00
WIP £2,670 £1,470 £1,470 45% 12,00.00
Total
Savings
£39,520
Total Investment:£5,000

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Presentation Template v.3.0
TP585-001Page9
Learning Outcomes
• Reflective Learning- How else could have I approached it?
• Good Engineer?
• Strategic Problem Solving
• Use of New Simulation Software
• Teamwork
• Decision Making
• Effective Communication

10. Restricted © Siemens plc 2013 All rights reserved.
I DT MC MF-CON
Presentation Template v.3.0
TP585-001Page9
Learning Outcomes
• Reflective Learning- How else could have I approached it?
• Good Engineer?
• Strategic Problem Solving
• Use of New Simulation Software
• Teamwork
• Decision Making
• Effective Communication