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Sirris manufacturingday2011 qrm-harol
The document provides an overview of Quick Response Manufacturing (QRM), detailing its implementation at Harol, a leading European producer of sunscreens, shutters, and doors. It covers the company’s history, the challenges it faced regarding variability and lead times, and how adopting QRM has improved production efficiency and competitiveness. Additionally, it discusses the integration of ERP systems to support QRM, leading to enhanced flexibility and synchronized operations.
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Sirris manufacturingday2011 qrm-harol
- 1. Kristof Souwens Process Manager, PMP Arthur Vandebosch Operations Manager Founding Father QRM
- 2. Overview 1 The Company (History) 2 Problem Statement 3 What is QRM ? 4 QRM at Harol 5 How ERP supports QRM 6 First Results & Future Perspectives Kristof Souwens, PMP
- 3. The Company (History) Started in 1946 (wooden shutters) One of the Leading European producers of sunscreens, shutters and sectional doors 320 employees Annual turnover = 44 million Euros Kristof Souwens, PMP 1 The Company (History)
- 4. The Company (History) Till 1993: MS DOS 1993: AS 400 - MRP • PUSH-system • No MRP for make-to-stock • WIP level = extremely high → Delivery Reliability ↘ → Lead Time = 5 wks 2000: AS 400 – LEAN (KANBAN) => Pull System • No MRP for make-to-stock • Production order produced by due date • Bottleneck planned with unlimited capacity • WIP buffer management through PULL-system • Delivery Reliability ↗ → Lead Time = 5 d 2010: Microsoft AX Dynamics => Push & Pull • Production order by print date • MRP for make-to-stock (through ERP implementation) • Bottleneck planned with limited capacity • WIP buffer management through CONWIP/KANBAN/POLCA) – MTO & MTS • Delivery Reliability ↗ → Lead Time = 2 d Kristof Souwens, PMP 1 The Company (History)
- 5. Problem Statement 3 DIMENSIONAL VARIABILITY STRATEGIC DIMENSION • Seasonality (Highly variable demand) • Product variety • Raw material cost (Aluminum) TACTICAL DIMENSION • Capacity planning (huge swings in capacity utilization) • “Cross-functional” production process (painting & textile cell) • Variety in shifts between different cells OPERATIONAL DIMENSION • Changeover times (color changes) • Special orders (rework, repair, …) • Unbalanced production lines ( partly Engineer-to-Order) Kristof Souwens, PMP 2 Problem Statement
- 6. What is QRM? QRM = Quick Response Manufacturing QRM is a companywide strategy, aimed at increasing flexibility and responsiveness by the continuous shortening the lead time, that pursues the reduction of lead time in all aspects of a company’s operations (Externally as Internally). A Competitive Strategy for High-Variability, Low-Volume or Custom- Engineered Products Based on business strategy of Time-Base Competition (TBC) Using speed to gain competitive advantage QRM implies Rapid delivery of existing products ALSO, rapid development and introduction of new products Source: Master class - Quick Response Manufacturing – Page 12-14 – Copyright © 2010 R. Suri Kristof Souwens, PMP 3 What is QRM ?
- 7. QRM : Thekey to gaining your Competitive Advantage Choice of Strategy QRM: Your Competitive Edge Exploit Lean/sigma Eliminate Tools Lean Type of Dysfunctional Strategic Variability Source: 2010, It’s About Time - The Competitive Advantage of Quick Response Manufacturing, Rajan Suri – p 5 Kristof Souwens, PMP 3 What is QRM ?
- 8. The Power ofTime Requires major PARADIGM SHIFT in management thinking Cost-Based Time-Based Lead Time drives everything Business understanding Decisions Measurements Source: Master class - Quick Response Manufacturing – Page 32 – Copyright © 2010 R. Suri Kristof Souwens, PMP 3 What is QRM ?
- 9. Organizational Structure The Response Time Spiral for make-to-order products Master Schedule: Planning organization decides to use longer Long Lead Need to plan way Times ahead lead times Regular Jobs Inaccuracy Delayed of Planning Loss of focus for regular jobs @ Past performance problems “Hot” Jobs, Safety Time Expediting Inserted Jobs started long before Unacceptabel High WIP and they are due, also some parts made but not used lead times, Inventory till much later planning orders Source: 2010, It’s About Time - The Competitive Advantage of Quick Response Manufacturing, Rajan Suri – p 40 Kristof Souwens, PMP 3 What is QRM ?
- 10. Organizational Structure Roots of the Spiral: Cost-Based Management Minimize Break into simple Low Skills, Functional Cost (specialized) steps Low Wages Departments Ensure Minimize Resources, Managers: Backlog, Maximize Efficiency, Minimize Cost Batching Maximize Utilization Long Feedback Loops, Poor Quality, Long Backtracking, Lead Times and Expediting OOPS! High Cost Can’t be controlled: must be killed! Focus on reducing the consumption of time throughout the system Source: 2010, It’s About Time - The Competitive Advantage of Quick Response Manufacturing, Rajan Suri – p 46 Kristof Souwens, PMP 3 What is QRM ?
- 11. KANBAN vs POLCA KANBAN KANBAN board M1 M2 KANBAN card POLCA (Paired Overlapping Loops with Cards of Authorization) B1 C1 C1 B1 B1 B1 A1 C1 C1 C2 B1 A1 B1 B1 C2 C2 Kristof Souwens, PMP 3 What is QRM ?
- 12. Implementation QRM Strategy DO’s: INSIDE-OUT approach Step-by-step Focusing on the things that already work (direct results) Continuously improving & optimizing the implemented system Expanding gained knowledge DONT’s: Not starting from Time-Based Competition Strategy (nor MCT) Trying to get stakeholders buy-in by preaching (only theory) Big BANG Kristof Souwens, PMP 4 QRM at Harol
- 13. Customized QRM Game KristofSouwens, PMP 3 QRM at Harol
- 14. QRM at HAROL Orders Buffer (Lacquer) Buffer Preparation (raw) Awnings Awnings Awnings - RAL Assembly Line - STD Awnings Buffer (Lacquer) - RAL Buffer (raw) Awnings Awnings - STD - STD Buffer Preparation (raw) - RAL VZ 8h 9h 10h 11h …. Buffer Textile Buffer Textile Standard Rush (Awnings) RS R Textile Dralon PAINTING Warehouse Textile MTS Standard (Screens,VZ,US) Textile Buffer (Lacquer) Screens, VZ, US 8h 9h 10h 11h …. Screens,VZ,US Kunstof Standard Buffer (raw) Rush Orders Screens, VZ,US Buffer (Lacquer) Screens/VZ/US - RAL Assembly Line - STD Buffer Preparation (raw) Screens/VZ/US - RAL Screens - RAL - STD Kristof Souwens, PMP 4 QRM at Harol
- 15. QRM at HAROL Orders Buffer (Lacquer) Buffer Preparation (raw) Awnings Awnings Awnings - RAL R Assembly Line - STD Awnings Buffer (Lacquer) R - RAL Buffer (raw) Awnings Awnings - STD - STD Buffer Preparation (raw) - RAL VZ 8h 9h 10h 11h …. Buffer Textile Buffer Textile Standard Rush (Awnings) SR R Textile Dralon PAINTING Warehouse Textile MTS Standard (Screens,VZ,US) Textile Buffer (Lacquer) Screens, VZ, US 8h 9h 10h 11h …. Screens,VZ,US Kunstof Standard Buffer (raw) Rush Orders Screens, VZ,US Buffer (Lacquer) Screens/VZ/US - RAL Assembly Line - STD Buffer Preparation (raw) Screens/VZ/US - RAL Screens - RAL - STD Kristof Souwens, PMP 4 QRM at Harol
- 16. QRM at HAROL Orders Buffer (Lacquer) Buffer Preparation (raw) Awnings Awnings Awnings - RAL R Assembly Line - STD Awnings Buffer (Lacquer) - RAL Buffer (raw) Awnings Awnings - STD - STD Buffer Preparation (raw) - RAL VZ 8h 9h 10h 11h …. Buffer Textile Buffer Textile Standard Rush (Awnings) SR R Textile Dralon PAINTING Warehouse Textile MTS Standard (Screens,VZ,US) Textile Buffer (Lacquer) Screens, VZ, US 8h 9h 10h 11h …. Screens,VZ,US Kunstof Standard Buffer (raw) Rush Orders Screens, VZ,US Buffer (Lacquer) Screens/VZ/US - RAL Assembly Line - STD Buffer Preparation (raw) Screens/VZ/US - RAL Screens - RAL - STD Kristof Souwens, PMP 4 QRM at Harol
- 17. QRM at HAROL S Orders Buffer (Lacquer) Buffer Preparation (raw) Awnings Awnings Awnings - RAL Assembly Line - STD Awnings Buffer (Lacquer) - RAL Buffer (raw) Awnings Awnings - STD - STD Buffer Preparation (raw) - RAL VZ 8h 9h 10h 11h …. Buffer Textile Buffer Textile Standard Rush (Awnings) R Textile Dralon PAINTING Warehouse Textile MTS Standard (Screens,VZ,US) Textile Buffer (Lacquer) Screens, VZ, US 8h 9h 10h 11h …. Screens,VZ,US Kunstof Standard Buffer (raw) Rush Orders Screens, VZ,US Buffer (Lacquer) Screens/VZ/US - RAL Assembly Line - STD Buffer Preparation (raw) Screens/VZ/US - RAL Screens - RAL - STD Kristof Souwens, PMP 4 QRM at Harol
- 18. QRM at HAROL Orders Buffer (Lacquer) Buffer Preparation (raw) Awnings Awnings Awnings - RAL Assembly Line S - STD Awnings Buffer (Lacquer) - RAL Buffer (raw) Awnings Awnings - STD - STD Buffer Preparation (raw) - RAL VZ 8h 9h 10h 11h …. Buffer Textile Buffer Textile Standard Rush (Awnings) Textile Dralon PAINTING Warehouse Textile MTS Standard (Screens,VZ,US) Textile Buffer (Lacquer) Screens, VZ, US 8h 9h 10h 11h …. Screens,VZ,US Kunstof Standard Buffer (raw) Rush Orders Screens, VZ,US Buffer (Lacquer) Screens/VZ/US - RAL Assembly Line - STD Buffer Preparation (raw) Screens/VZ/US - RAL Screens - RAL - STD Kristof Souwens, PMP 4 QRM at Harol
- 19. How ERP supportsQRM – Past State Order entry Logistics MTO MTS Independent (duplicated) authorizations Unsystematic MTS MRP planning Unlimited Capacity Planning Planning Preperation Cell Painting Cell No synchronization between production cells No possibility to level out Execution Assembly Cell order intake No mixed model Textile Cell scheduling Kristof Souwens, PMP 5 How ERP supports QRM
- 20. How ERP supportsQRM – Current & Future State Order entry Logistics MTO MTS 1 authorization point Planning ERP Systematic MTS planning Capacity (Skill) Planning Limited capacity planning MRP Employee flexibility ↑ High synchronization between cells Preperation Cell Painting Cell Leveling out order intake Execution Automated mixed model Assembly Cell scheduling Textile Cell Kristof Souwens, PMP 5 How ERP supports QRM
- 21. First Results QRM Implementation Kristof Souwens, PMP 6 First Results & Future Perspectives
- 22. Rajan Suri’s visitat Harol Kristof Souwens, PMP 6 First Results & Future Perspectives
- 23. Future Perspective (Strategy) CUSTOMER INTIMACY Customer Focused Strategic Growth Quality & Service Speed Time-Based Competition QUICK RESPONSE MANUFACTURING Kristof Souwens, PMP 6 First Results & Future Perspectives
- 24. Future Perspective (Strategy) QUICK RESPONSE MANUFACTURING Time-Based Competition in office operations => Q-roc Speed Quality & Service Strategic Growth Customer Focused CUSTOMER INTIMACY Kristof Souwens, PMP 6 First Results & Future Perspectives
- 25. More info onQuick Response Manufacturing It’s About Time: The Competitive Advantage Quick Response Manufacturing: A of Quick Response Manufacturing, by R. Companywide Approach to Reducing Lead Suri, CRC Press, 2010. Times, by R. Suri, Productivity Press, 1998. Kristof Souwens, PMP 1 What is QRM ?
- 26.