March19th,2010
EmbraerDay
IndustrialOperationsOverview
ArturCoutinho
IndustrialOperations
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
EmbraerEnterpriseExcellenceProgram
TransformationManagement
Lean
Enterprise
LeadershipPeople
Macro-StrategyCulture
Executi...
EmbraerEnterpriseExcellenceProgram
Culture–EmbraerValues
EmbraerEnterpriseExcellenceProgram
2009EmployeeClimateSurvey
HighLevelofEmployeeSatisfaction
360ºLeadershipSurvey
TechnicalExpertiseBusiness
Management
Managementby
Results
FocusonCustomerPeopleManagementTeamworkBeh...
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
1Q07–BottlenecksManagement
Flight
Preparation
Flight
Preparation
Sub-Assy
BOT
Sub-Assy
BOT
StructuralandFinalAssemblyStruc...
1Q10–BottlenecksManagement
Flight
Preparation
Flight
Preparation
TubingTubing
LaborLabor
OutsourcingOutsourcing
PaintingPa...
EmbraerDay2008
2007-2008BotucatuPlant–Investments
BOTPlantExpansion
SkinPanel
Fabrication
Hangar
BotucatuPlant:2008-2009Highlights
Newsheet
metalfacility
Phenom100&300
structuralassembly
Panelsstructural
assembly
NewSheetMetalFacility
100%Operational100%Operational
PaintingPainting
ChemicalMillingChemicalMillingStretchFormingStretchF...
Phenom100&300WingAssembly
3Q093Q09
PhenomPhenom100&300structuralassemblyhangars:Fullrateproduction100&300structuralassembl...
Phenom100&300ProductionReadiness
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
AutomationInitiatives(2/3)
AutomationInitiatives(3/3)
UltrasoundRobotUltrasoundRobot
OperationalsinceJan/10OperationalsinceJan/10
PlannedPlanned Impl...
FullyautomatedSurfaceTreatmentLine
AutomationInitiatives-ELEB
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
LeanPhilosophyConcepts
Continuousflow
Oneshipsetflow
PullSystem
Materialsclosetothepointofuse
Workingcell
Setuptimereducti...
LeanResults–KaizenProjects
KaizensProject
0
200
400
600
800
1.000
1.200
2007200820092010
1,057Kaizenprojects
uptoMarch17th...
LeanResults–ContinuousImprovementCells
0
100
200
300
400
TotalLaunchQualificationBronzeSilver
NumberofCells
2010targetAchi...
LeanResults–EJetsFinalAssembly
LeanResults–EJetsFinalAssembly
13docks,decentralizedoperations13docks,decentralizedoperations
dock
2008
LeanResults–EJetsFinalAssembly
SignificantsimplificationofproductionflowSignificantsimplificationofproductionflow
Transiti...
LeanResults–PartsSupplyImprovements
CurrentCurrentBeforeBefore
LeanConceptappliedtoStorageandPartsSupplyLeanConceptapplied...
LeanResults–PartsSupplyImprovements
Material/ToolsStorageUseofKits/FlowRacks
CurrentCurrentBeforeBefore
LeanResults–ProductionSequencing&RFID*
RFIDSystemRFIDSystem
*RadioFrequencyIdentification*RadioFrequencyIdentification
EJe...
LeanResults–“ZeroMissingItems”Program
KeyfactorforreducingproductioncycleKeyfactorforreducingproductioncycle
1H072H071H082...
200720082009
SignificantcostandwastereductionSignificantcostandwastereduction
LeanResults–ManufacturingQualityImprovements...
LeanResults–InventoryEvolution
LeanResults–OvertimeReduction
jan
feb
mar
apr
may
jun
jul
agu
sep
oct
nov
dec
jan
feb
mar
apr
may
jun
jul
agu
sep
oct
nov
...
EmbraerDay2008
•P3ELaunch-EmbraerEnterpriseExcellenceProgram
•ProductionBottlenecksManagement
•InvestmentsinExistingSites
...
RecentlyLaunchedIndustrialUnits
Melbourne,
Florida
Évora,
Portugal
•Phenom100&300
FinalAssemblyLine
•CompletionCenter
•Pai...
PaperlessEnvironment
ProposedProposedCurrentProcessCurrentProcess
DigitalMock-up
2DDrawing
Paperless
Environment
DigitalIn...
CEsConstructionStatus–Jan/10
ThankYou!
ReadytoTakeoff!
Industrial Operations
Industrial Operations
Industrial Operations
Industrial Operations
Industrial Operations
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Industrial Operations

  1. 1. March19th,2010 EmbraerDay IndustrialOperationsOverview ArturCoutinho IndustrialOperations
  2. 2. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  3. 3. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  4. 4. EmbraerEnterpriseExcellenceProgram TransformationManagement Lean Enterprise LeadershipPeople Macro-StrategyCulture Executive Committee
  5. 5. EmbraerEnterpriseExcellenceProgram
  6. 6. Culture–EmbraerValues
  7. 7. EmbraerEnterpriseExcellenceProgram
  8. 8. 2009EmployeeClimateSurvey
  9. 9. HighLevelofEmployeeSatisfaction
  10. 10. 360ºLeadershipSurvey TechnicalExpertiseBusiness Management Managementby Results FocusonCustomerPeopleManagementTeamworkBehavior"Lean"Thinking 3.303.30 3.203.20Target(80%) Embraer’sResult MaximumRate4.004.00
  11. 11. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  12. 12. 1Q07–BottlenecksManagement Flight Preparation Flight Preparation Sub-Assy BOT Sub-Assy BOT StructuralandFinalAssemblyStructuralandFinalAssembly SheetMetal SJK SheetMetal SJK SheetMetal BOT SheetMetal BOT CabinetryShop GPX CabinetryShop GPX DeliveriesDeliveries FinalAssy.FinalAssy.Fuselage Equipage Fuselage Equipage Matingand Complem. Matingand Complem.SegmentsSegments WingAssy.
  13. 13. 1Q10–BottlenecksManagement Flight Preparation Flight Preparation TubingTubing LaborLabor OutsourcingOutsourcing PaintingPainting MachiningMachining Sub-Assy BOT Sub-Assy BOT StructuralandFinalAssemblyStructuralandFinalAssembly ChemicalMillingChemicalMilling SheetMetal SJK SheetMetal SJK HarnessHarness SuppliersSuppliers SheetMetal BOT SheetMetal BOT CabinetryShop GPX CabinetryShop GPX CompositeComposite DeliveriesDeliveries FinalAssy.FinalAssy.Fuselage Equipage Fuselage Equipage Matingand Complem. Matingand Complem.SegmentsSegments WingAssy.WingAssy.WingEquipageWingEquipage PhenomPhenomFamilyFamily Fuselage Equipage Fuselage EquipageFinalAssy.FinalAssy.Matingand Complem. Matingand Complem.SegmentsSegments ERJ145PlatformERJ145Platform WingAssy.WingAssy.WingEquipageWingEquipageTankAssy.TankAssy. E170/190 FinalAssy.Line E170/190 FinalAssy.Line Fuselage Equipage Fuselage EquipageFuselageMatingFuselageMating WingEquipageWingEquipageE170WingE170Wing SegmentsSegments WingEquipageWingEquipage E170/190/Lineage1000E170/190/Lineage1000 E190WingE190Wing Bottlenecks Attention UnderControl
  14. 14. EmbraerDay2008
  15. 15. 2007-2008BotucatuPlant–Investments BOTPlantExpansion SkinPanel Fabrication Hangar
  16. 16. BotucatuPlant:2008-2009Highlights Newsheet metalfacility Phenom100&300 structuralassembly Panelsstructural assembly
  17. 17. NewSheetMetalFacility 100%Operational100%Operational PaintingPainting ChemicalMillingChemicalMillingStretchFormingStretchFormingStringerMillingStringerMilling ThermalTreatmentThermalTreatmentCNCFinishingCNCFinishing
  18. 18. Phenom100&300WingAssembly 3Q093Q09 PhenomPhenom100&300structuralassemblyhangars:Fullrateproduction100&300structuralassemblyhangars:Fullrateproduction
  19. 19. Phenom100&300ProductionReadiness
  20. 20. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  21. 21. AutomationInitiatives(2/3)
  22. 22. AutomationInitiatives(3/3) UltrasoundRobotUltrasoundRobot OperationalsinceJan/10OperationalsinceJan/10 PlannedPlanned ImplementedImplemented PhenomPhenom100EHDrilling100EHDrilling Robot:Robot:OperOper.sinceDec/08.sinceDec/08 Monorail:Monorail:OperOper.sinceMay/09.sinceMay/09
  23. 23. FullyautomatedSurfaceTreatmentLine AutomationInitiatives-ELEB
  24. 24. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  25. 25. LeanPhilosophyConcepts Continuousflow Oneshipsetflow PullSystem Materialsclosetothepointofuse Workingcell Setuptimereduction VisualManagement(AndonPhilosophy) Zerodefect PokaYoke Movingtooling(lines) Nomanualhandling Actionstoeliminatethe7wastes Inappropriate Processing Rework Over Production Inventory Waiting Time Excessive Material Handling Operator Movement 7Wastes
  26. 26. LeanResults–KaizenProjects KaizensProject 0 200 400 600 800 1.000 1.200 2007200820092010 1,057Kaizenprojects uptoMarch17th,2010 SignificantIncreaseinSignificantIncreasein NumberofNumberofKaizensKaizens CustomerSupport Engineering Administrative IndustrialOperations
  27. 27. LeanResults–ContinuousImprovementCells 0 100 200 300 400 TotalLaunchQualificationBronzeSilver NumberofCells 2010targetAchieved!
  28. 28. LeanResults–EJetsFinalAssembly
  29. 29. LeanResults–EJetsFinalAssembly 13docks,decentralizedoperations13docks,decentralizedoperations dock 2008
  30. 30. LeanResults–EJetsFinalAssembly SignificantsimplificationofproductionflowSignificantsimplificationofproductionflow Transition–1Q09 dock
  31. 31. LeanResults–PartsSupplyImprovements CurrentCurrentBeforeBefore LeanConceptappliedtoStorageandPartsSupplyLeanConceptappliedtoStorageandPartsSupply
  32. 32. LeanResults–PartsSupplyImprovements Material/ToolsStorageUseofKits/FlowRacks CurrentCurrentBeforeBefore
  33. 33. LeanResults–ProductionSequencing&RFID* RFIDSystemRFIDSystem *RadioFrequencyIdentification*RadioFrequencyIdentification EJetsEJetsFinalAssemblyLineFinalAssemblyLineLegacy650FinalAssemblyLineLegacy650FinalAssemblyLine
  34. 34. LeanResults–“ZeroMissingItems”Program KeyfactorforreducingproductioncycleKeyfactorforreducingproductioncycle 1H072H071H082H081H092H09 85% PNsPNs
  35. 35. 200720082009 SignificantcostandwastereductionSignificantcostandwastereduction LeanResults–ManufacturingQualityImprovements 89% NonNon--Conformities(monthlyaverage)Conformities(monthlyaverage) 57%
  36. 36. LeanResults–InventoryEvolution
  37. 37. LeanResults–OvertimeReduction jan feb mar apr may jun jul agu sep oct nov dec jan feb mar apr may jun jul agu sep oct nov dec jan feb mar apr may jun jul agu sep oct nov dec 200820092010 Planned SignificantOvertime Reduction
  38. 38. EmbraerDay2008 •P3ELaunch-EmbraerEnterpriseExcellenceProgram •ProductionBottlenecksManagement •InvestmentsinExistingSites •ProductionReadinessforPhenom100Ramp-up •AutomationInitiativesPlanning •IntroductionofLeanConcept •LeanInitiativesResults •LookingtotheFuture
  39. 39. RecentlyLaunchedIndustrialUnits Melbourne, Florida Évora, Portugal •Phenom100&300 FinalAssemblyLine •CompletionCenter •PaintBooth •CustomerCenter •Compositeand MetallicCentersof Excellence •StateoftheArt ManufacturingProcess •NewTechnologiesApplication MelbourneMelbourne ÉÉvoravora MetallicComposite
  40. 40. PaperlessEnvironment ProposedProposedCurrentProcessCurrentProcess DigitalMock-up 2DDrawing Paperless Environment DigitalInterfaceDigitalInterface
  41. 41. CEsConstructionStatus–Jan/10
  42. 42. ThankYou! ReadytoTakeoff!

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