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Tower Manufacturing Operations Caso de éxito
     TOWER BACKGROUND Tower Automotive is a leading integrated global manufacturer of engineered structural metal components and assemblies. The company supplies the automotive industry with body-structure stampings, frames and other chassis structures, as well as complex welded assemblies for small and large cars, crossovers, pickups and SUVs. In the early decade of 2000,  the company was declared bankrupt. It was bought by an investment fund, the new owners immediately defined Tower’s main problems, those were high inventory levels and low profitability so they started a corporate program in order to improve the company’s performance. The transformation program included 6 Sigma and continuous improvement LVC was hired by Tower in 2008 to support it’s new continuous improvement program and bring fast and sustainable results to the company. For  this purpose, LVC has intervened in the following Tower plants : one in Belgium, three in Germany, three in Italy, one in Slovakia, one in Poland, two in Brazil, one in China, one in Korea and the development of a new factory in the US.
     TOWER OBJECTIVE Stop the leakage of negative profitability and largely reduce the inventory through a Lean Enterprise Transformation in order to provide: Support for the strategy of EBT*combined with inventory reduction and  market share growth. * Earningbeforetax
     TOWER RESULTS By the time LVC began working with Tower, the company was facing problems related with high levels of inventory and low profitability. After three years they have improved to  two digits in  EBT and a very  low levels of inventory, much less than twenty days on hand. ,[object Object]
Global Savings:
2008	$7.6M USD
2009	$17.9M USD
2010	$21.1M USD (Estimated savings)

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Caso Tower Automotive

  • 2. TOWER BACKGROUND Tower Automotive is a leading integrated global manufacturer of engineered structural metal components and assemblies. The company supplies the automotive industry with body-structure stampings, frames and other chassis structures, as well as complex welded assemblies for small and large cars, crossovers, pickups and SUVs. In the early decade of 2000, the company was declared bankrupt. It was bought by an investment fund, the new owners immediately defined Tower’s main problems, those were high inventory levels and low profitability so they started a corporate program in order to improve the company’s performance. The transformation program included 6 Sigma and continuous improvement LVC was hired by Tower in 2008 to support it’s new continuous improvement program and bring fast and sustainable results to the company. For this purpose, LVC has intervened in the following Tower plants : one in Belgium, three in Germany, three in Italy, one in Slovakia, one in Poland, two in Brazil, one in China, one in Korea and the development of a new factory in the US.
  • 3. TOWER OBJECTIVE Stop the leakage of negative profitability and largely reduce the inventory through a Lean Enterprise Transformation in order to provide: Support for the strategy of EBT*combined with inventory reduction and market share growth. * Earningbeforetax
  • 4.
  • 9. Productivity increased 54% in some sites in 2009*
  • 10. Business increased $15M USD in some sites due to efficiency increases
  • 13.
  • 24. FUTURE STATEVALUE STREAM MAP MANUFACTURING SYSTEMS
  • 25. TOWER RESULTS - FLEXIBILITY SMED 17 min 14 min 12 min Setup Time 38’48” 1º Setup Setup Time 24’50” 36% Improvement 2º Setup Setup Time 19’50” 3º Setup 49% Improvement 6
  • 26. TOWER RESULTS - PRODUCTIVITY Before 5 Operators/Shift 2 Shifts After 4 Operators/Shift 1 Shift 60% ProductivityImprovement Área Disponible
  • 27. TOWER RESULTS – PRODUCTIVITY OP10 OP20 OP30 OP40 ANTES 4 MO 90 PÇS/H Aqui é feita simultaneamente o item SUB65157 DEPOIS 3 MO 103 PÇS/H + 103 PÇS/H DO SUB65157 OP10 OP20 OP30 OP40 PRODUCTIVITY 200%