Production System Improvement in a changing environment Dr.-Ing. Frank Rick

Transcription

1 Production System Improvement in a changing environment Dr.-Ing. Frank Rick Aero Engines Maintenance and Production DGLR Conference / Hannover

2 Challenges for for the the aerospace industry Challenges for for the the companies Safety Environment: reduction of Fuel consumption Emissions Noise Efficiency: reduction of Investment cost Operational cost Development and Industrialization of innovative technologies and products Optimization of developmentprocesses and production processes concerning Time Cost Quality Frank Rick: DGLR - Aero Engines Maintenance and Production 2

3 The top-companies operate with production improvement programs - DCPS - TPS - HIPS - ACE - Six Sigma - Production improvement program does not necessarily lead to excellence BUT All top-companies operate with production improvement programs Frank Rick: DGLR - Aero Engines Maintenance and Production 3

4 Without standardization a continuous improvement is impossible improvement PERFORMANCE obstacle standardization Frank Rick: DGLR - Aero Engines Maintenance and Production 4

5 FAST is the production improvement program of MTU Aero Engines Goal Goal is to make MTU Aero Engines a competitive enterprise operating with efficient processes and methods How could it be achieved? Through appliance of adequate procedures which certainly lead to improvement in productivity (FAST-methods) What could be useful? A "Toolbox" that comprises all relevant methods applicable in the specific area (FAST-systems) Efficiency is simply to do the job using the best method not the next best (Henry Ford) Frank Rick: DGLR - Aero Engines Maintenance and Production 5

6 FAST-systems support in optimizing the MTU processes Market system Development system Value added process Production & purchase system Maintenance system Efficiency increase in program's management & customer service Efficiency increase in development process Optimizing of production, logistic & purchase Optimizing of product maintenance processes Optimizing of technology & innovation processes Management process Management & human resources system Constant improvement of processes in the areas: management, human resources, corporate quality, corporate communication, finance & controlling as well as in infrastructure / support Frank Rick: DGLR - Aero Engines Maintenance and Production 6

7 FAST-systems are a toolbox, FAST-methods are tools Example of FAST-system Production system Use of FAST-systems Centralized access to best-practice methods Review of all methods Uniform description of all methods Controlled application of methods Tools for development Storage of knowledge and know-how Example of FASTmethod APS" - Short description - Responsible person - Back-up needed Use of FAST-methods Standardization in MTU Method owner as expert Centralized access to checklists, documentation and regulations. Centralized access to training Frank Rick: DGLR - Aero Engines Maintenance and Production 7

8 The intranet provides guidance for the application of the FAST-systems Link to the systems Overall view of the production and purchase system Frank Rick: DGLR - Aero Engines Maintenance and Production 8

9 The intranet provides guidance for the application of the FAST-systems Short description of methods Download tool (method additional info) Frank Rick: DGLR - Aero Engines Maintenance and Production 9

10 The production system include organizational and process oriented methods Cost IP3E-teams (Simultaneous Engineering) PKM: Product-Cost-Management Time Flowline with pull-production Kaizen Quality Process-Integration Q-inspection Poka Yoke Basic functions Teamwork in production SOS: Sicherheit, Ordnung, Sauberkeit Frank Rick: DGLR - Aero Engines Maintenance and Production 10

11 Example: SOS (Sicherheit Ordnung Sauberkeit) 5s-checklist: Sort Straighten Shine Standardize Sustain Frank Rick: DGLR - Aero Engines Maintenance and Production 11

12 Example: PKM (product-cost-management) in the IP3E-team Design-change in series-production: edge of a cooling hole before before (high (high dpm): dpm): new: new: radius & chamfer radius R0,4-0,8 proposal proposal on on design-change: design-change: standardradius R0,2-0,8 rejected parameter parameter air air flow flow rate rate strength strength producibility producibility change change same same or or improved improved improved improved much much improved improved Frank Rick: DGLR - Aero Engines Maintenance and Production 12

13 Example: Setup-Kaizen Proceeding 1. record actual setting 2. identify wasting 3. eliminate combine change - simplify 4. identify internal and external steps for setting up 5. change internal to external steps 6. improve remaining steps 7. use 5s-checklist 8. parallel setting up 9. standardization 5 actual setting total way = 408 meter Frank Rick: DGLR - Aero Engines Maintenance and Production 13

14 Example: Poka Yoke before new wrong location right location Poka-Yoke device Only the right location is visible Frank Rick: DGLR - Aero Engines Maintenance and Production 14

15 The Prodction-System was implemented by a team ahead by top management COO controllingboard VP vane and plate production (TS) VP rotor stator production (TT) VP purchasing (TL) Director FAST Senior Project Manager FAST-Team Senior Manager TS Senior Manager TT Senior Manager TL project team Supportteam Supportteam Supportteam Specialist for method support and consulting Frank Rick: DGLR - Aero Engines Maintenance and Production 15

16 Ten important points to success Top Top managment managmenthas has to to lead lead the the implementation implementation (Top-Down) (Top-Down) Support Support conception conception and and implementation implementation by by a cental cental project project group group Integrate Integrate employees employees and and management management in in the the conception conception and and implementation implementation phase phase Integrate Integrate workers workers council council Prove Prove success success by by pilots pilots Communicate Communicate proceeding proceeding and and results results to to the the employees employees Realize Realize fast fast and and visible visible success success in in the the beginning beginning (z.b. (z.b. 5S 5S // SOS) SOS) Audit Audit implementation implementation and and monitor monitor results results Launch Launch improvement improvement systems systems companywide companywide in in several several steps steps Implement Implement methods methods oriented oriented on on results results Frank Rick: DGLR - Aero Engines Maintenance and Production 16

17 The success of the continuous improvement is reflected in the numbers Reference (Total sum) Development DPM (Defects per million) - 45 % Customers complaints - 74 % Turnover per employee + 30 % Average of work-related accidents - 33 % Continuous improvement contribution per employee % Frank Rick: DGLR - Aero Engines Maintenance and Production 17

18 Next steps for the FAST-systems connecting to MTU s process world Access to processes including all relevant specifications, standards and methods on one plattform FAST methods Standard Specs Input Processstep Output Control Frank Rick: DGLR - Aero Engines Maintenance and Production 18

19 Thank you for your attention Dr.-Ing. Frank Rick MTU Aero Engines GmbH & Co. KG Production Components Production Planning Phone: Fax: Frank Rick: DGLR - Aero Engines Maintenance and Production 19