Sikeres projekttel Indiában

Átírás

1 Sikeres projekttel Indiában Meleg Edit QC koordinátor SMR Automotive Mirror Technology Hungary Bt. a member of SAMVARDHANA MOTHERSON GROUP

2 SMG csoport jelenlét 25 országban több mint 140 telephely UK IRELAND Engineering & Design Wiring Harness Mirrors CZECH REPUBLIC SLOVAKIA HUNGARY GERMANY Plastic moulding Plastic moulding Mirrors Mirrors Plastic moulding Metal Machining Representative Office Russia Mirrors USA CHINA Mirrors Representative Office MEXICO SOUTH KOREA Mirrors Wiring Harness Mirrors Plastic moulding Wiring Harness SPAIN Mirrors Plastic moulding Sintered Metal Parts JAPAN Mirrors Wiring Harness PORTUGAL Plastic moulding THAILAND Mirrors Wiring Harness SRILANKA Wires FRANCE Mirrors SINGAPORE Strategic Sourcing BRAZIL Mirrors Plastic moulding MAURITIUS AUSTRIA ITALY Engineering & Design Representative Office SOUTH AFRICA SMR_PPT _MSO7_1203_Master Mirrors Plastic moulding Representative Office Plastic moulding UAE Wiring Harness Plastic moulding Injection moulding Tools Silicon Rubber Injection moulding SMR is a member of SAMVARDHANA MOTHERSON GROUP AUSTRALIA Mirrors Rubber Extrusion Waste Recycling Systems Engineering & Design 2

3 Az SMG autóipari specialista Termékportfólió (beleértve a vegyesvállalatokat) Napfénytető B-oszlop borítás Belső lámpa A-oszlop borítás Ajtó borítás Belső kilincs Műszerfal Biztosíték doboz HTC Kábelek Rögzítők Csatlakozók Levegő tisztító egység Akkumulátor tálca Kompresszor Hűtőrács Lengéscsillapító kar Első fényszóró Lökhárító Tető nyitó C-oszlop borítás Tető sín Spoiler Kormányoszlop borítás Üzemanyag töltő sapka Hátsó világítás Díszítő csík Kipufogó felfüggesztés Kerékagy sapka Külső kilincs Külső tükör Papucs lemez Doboz alsó konzol Belső tükör Pedál doboz egység HVAC rendszerek SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 3

4 SMG Kulcsmutatók Motherson alapította 1975-ben képzett munkavállaló Group Turnover ($US billion)* Sales split by product Wiring Harness 19.6% Mirrors 26.6% Modules, Polymer Processing & Tooling 49.2% Elastomer Processing 1.0% IT & Design 0.4% Metal Working 1.2% Manufacturing Support 0.4% Others 1.7% *2011/12 Approximate annualized number (includes full year turnover of Peguform / SMP which entered the group in November 2011) SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 4

5 SMR - Földrajzi áttekintés USA Tükör MEXIKÓ Tükör UK Tükör 14 Ország 20 Gyár NÉMETORSZÁG Központ Értékesítés Mérnökség MAGYARORSZÁG Tükör Mérnökség 7400 motivált munkaerő KÍNA Tükör Nemzetközi beszerzés DÉL-KOREA Tükör JAPÁN Mérnökség és Marketing SPANYOLORSZÁG Tükör FRANCIAORSZÁG Tükör THAIFÖLD Tükörlap gyártás Tükör BRAZÍLIA Tükör INDIA Tükör Mérnökség AUSZTRÁLIA Tükör Mérnökség SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 5

6 Értékesítés in % növekedés 18% növekedés 12% növekedés 25% növekedés * Gross Sales as per Management Accounts SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 6 6

7 Értékesítés országok szerint SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 7

8 Az SMR Hungary gyártóbázisai 1-es gyár Mosonszolnok 2-es gyár Mosonmagyaróvár Labor Győr Logisztikai központ Hegyeshalom SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 8

9 Az 1. számú gyár technológiai információi Fröccsöntés Festés Összeszerelés TELJES TERÜLET 2000 m 2 TELJES TERÜLET 2000 m 2 TELJES TERÜLET 3000 m 2 KAPACITÁS 17 millió db/év KAPACITÁS 7,1 millió db/év KAPACITÁS 7,3 millió db/év TERMÉKEK MŰANYAG ALKATRÉSZEK TERMÉKEK LAKKOZOTT ALKATRÉSZEK TERMÉKEK KÜLSŐ ÉS BELSŐ TÜKRÖK Teljes termelési kapacitás = autó/év SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 9

10 Az 2. számú gyár technológiai információi Fröccsöntés Festés Összeszerelés TELJES TERÜLET 1800 m 2 TELJES TERÜLET 1600 m 2 TELJES TERÜLET 2100 m 2 KAPACITÁS 15 millió db/év KAPACITÁS 7,5 millió db/év KAPACITÁS 6 millió db/év TERMÉKEK MŰANYAG ALKATRÉSZEK TERMÉKEK LAKKOZOTT ALKATRÉSZEK TERMÉKEK KÜLSŐ ÉS BELSŐ TÜKRÖK Teljes termelési kapacitás = autó/év SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 10

11 QUALITYCIRCLE SMR Automotive Mirror Technology Hungary Bt. a member of SAMVARDHANA MOTHERSON GROUP

12 Bemutatkozás SMR HU team NOS team részt vett Delhiben a döntőn 10. helyezést érte el, a legjobb külföldi helyezést SMR HU team célunk ismét döntőbe jutni és helyezést elérni A QC teamek száma és területenkénti megoszlása t 1 (Mosonszolnok) t 2 (Mosonmagyaróvár) t 1+2 közös Lakkozó Fröccsöntő év május június július augusztus szeptember Szerelde Vevői Quality HR Beszerzés hónap összesen SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 12

13 A teamek státusza október Lépés Résztvevő Határidő Felelős Distillers Javaslat a teamre managers managers QC rövid bemutatása team leaders week 22 Edit Team megalakítása, jelentkezés team leaders week 23 Edit Oktatás A projekt futása team members week Edit team members week facilitator step 1 Probléma azonosítás team members week facilitator step 2 Probléma kiválasztása team members week facilitator step 3 Probléma definiálása team members week facilitator step 4 Probléma elemzése team members week facilitator step 5 Okok azonosítása team members week facilitator step 6 Gyökérok elemzés team members week facilitator step 7 Adat elemzés team members week facilitator step 8 Megoldás fejlesztése team members week facilitator step 9 Megvalósíthatóság, bevezethetőség team members week facilitator step 10 Teszt bevezetés step 11 Végleges bevezetés step 12 Áttekintés Vezetőségi áttekintés 1 team members week facilitator team members week facilitator team members week facilitator team leader and facilitator 45% Scrap Hunter 60% Seven Stars Pirates of SMR Colour 67% 67% 67% Golden Sack 60% T E A M S SMARTS SMURFS HungaRy 67% 75% 50% Starfighte Supercha First Run rs sing Rushers 67% 45% 50% Target Finders 45% IQ Fighters 50% NOS No More Scratch 45% 45% Edit KW 45 KW 42 KW 38 KW 40 KW 41 KW 41 KW 39 KW 38 KW 43 KW 40 KW45 KW 42 KW 44 KW 43 KW 45 KW 44 Vezetőségi áttekintés 2 team leader and facilitator Edit KW 49 KW 47 KW 45 KW 46 KW 46 KW 47 KW 45 KW 45 KW 48 KW 46 KW 49 KW 47 KW 48 KW 48 KW 49 KW 49 Támogatás team members week Edit Projekt lezárása team members week Edit Prezentáció elkészítése team members 2014 facilitator Bemutató elkészítése team members 2014 facilitator Team alakítás, oktatások Team jelenlegi előrehaladás Vezetőségi áttekintés SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 13

14 Management review, trainings Teamtagok: 84 team tag dolgozik a 16 csapatban Menedzsment áttekintés: hetente hétfőnként 2 team bemutatkozik team oldaláról lehetőség a munkájukról beszélni, szerepelni, prezentálni, az elvégzett munka fontosságát, eredményét hitelesen bemutatni A menedzsment oldaláról a team megismerése, segítése, támogatása A vezetés maximális támogatásával segíti a teameket céljuk elérésében, fontosak számára a sikeres projektek, a fejlődés és az összetartozás. A fő cél: a team tagok összekovácsolódása, szisztematikus munka tényeken, számokon alapuló elemzés módszerek megismerése és alkalmazása az előttük álló fejlesztendő feladat felismerése, és a gyökér ok meghatározása (sosem a felszínt kell elsimítani, azt kell megtalálni, mi gerjeszti a hullámokat) ötletes, hasznos, valódi megoldás megtalálása és bevezetése tanulni, együtt dolgozni, fejlődni, jobbnak lenni SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 14

15 Management review, trainings magyar teamek Hírek az SMR világából: a többi gyár QC teamjei koreai team kínai team angol team spanyol team indiai team ausztrál team Professor Quincy Chippendale 1. Kérdés: ki ő a képen, aki Quality Guru, ő dolgozta ki a minőségfejlesztés 14 lépését, az ő nevéhez fűződik a Zero Defect program. 2. Kérdés: mi az a szó, folyamatos jobbítást jelent, állandó változást, fejlődést, mi is gyakran használjuk, és japánul itt jobbra látható 3. Egy anagramma játék: Cleric say quilt. SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 15

16 THE COMPASS TEAM Quality Circle Regional Final Hungary 2013 SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 16

17 Team motto Compass: Gives direction! People from different continents found each other! Cultures came together! Compass: basic tool to use Vaastu success! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 17

18 Team introduction Team members: István Szarka János Rábai Márió Végh Edit Meleg Ferenc Szilágyi Szabolcs Korpáczy Péter Nagy Operator Operator Operator Quality Engineer Process Engineer Process Engineer Program Manager Edit Meleg Ferenc Reifmesser Gábor Pataky QC Team Leader Facilitator Co-ordinator SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 18

19 Team frame Team: Compass Project name: Reduce damages in Mercedes assembly line Meeting Step Activity Date (Week) IDENTIFICATION OF PROBLEM Pareto, Brainstorming, KJ 2 PROBLEM SELECTION ABC 3 PROBLEM DEFINITION Visual monitoring, Failure mapping, Flow Chart 4 PROBLEM ANALYSIS Databank, Statistical analysis 5 IDENTIFICATION OF CAUSES Brainstorming, Priorisation 6 ROOT CAUSE ANALYSIS Cause & Effect Diagram, 5 Why 7 DATA ANALYSIS Data analysis, ROI calculation 8 SOLUTION DEVELOPMENT PDCA 9 FORESEEING THE POSSIBLE RESISTANCE Pilot Process 10 TRIAL IMPLEMENTATION Trial Process 11 REGULAR IMPLEMENTATION Regular application 12 FOLLOW UP/REVIEW Risk analysis 18 meetings were during the time period of Quality Circle On Wednesdays and more meetings close to end of project Participation rate: 100% SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 19

20 1. Identification of problem Brainstorming on the production line using K J method we classified all the observations SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 20

21 1. Identification of problem Pareto analysis: scrap quantity Mercedes assembly line April- July Visual Inspection Electrical Testing 144 SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 58 Total

22 2. Problem selection A B C Base cover damage assembly Housing damage Housing painting painting Base cover painting painting Lower Housing damage Lower housing painting painting Glass damage assembly Base cover injection moulding Indicator damage supplier Housing injection moulding Indicator assembling Indicator dirty supplier Blende injection moulding 2 K sealing position supplier Base cover deformation moulding Heating harness position Lower cover damage supplier Actuator position supplier Door sealing position assembly Housing polishing Index rework supplier 3M missing assembly Canbe solvedbyteam independently! Damage of Housing ABC Classification : Damageof Lower Housing Prioritize the problems using A B C A Minimum involvement of other departments in solving them. B Involvement of other departments is a necessary C Management sanction may be needed in implementing the solution. SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 22

23 3. Problem definition Failure mapping / visualisation What? Where? How big? How often? Marking the damages on one single Master Part for period of 2 weeks. Lower Housing SMR_PPT _MSO7_1203_Master Housing SMR is a member of SAMVARDHANA MOTHERSON GROUP 23

24 Team target Target: To reduce the damage at Mercedes Mirrorassembly process by 33% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Before Target Howwemade ithappen? SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 24

25 3. Problem definition Prozess Flow Kostenstelle : Erste Ausgabe : Aktuelle Ausgabe Datum : Dokument Nummer : Erstellt : S E7100-M1138-R Projekt Name: Daimler W246 Projekt Nummer: 623 Prozess : ASP Montage T eilenummer : 623.xxx F Szilágyi, E Meleg Start 10. Ei nkauf N acharbeit Träger Beiklappantrieb Kabelsatz Schraube (4 x) Fett ( nur EC und BSM ) 49. Kont rolle NO K S OK 50. Start etiket t kontrolieren,g rundplatte in H and nehmen, in Schablone legen. G A Antrieb in H and nehnem, mit Kabelsatz kontakt ieren, GA in Träger legen. R ast scheibe entnehm en. Verschraubung 4x. R astscheibe auf G A legen. Vormontierte Baugruppe aus der Schablone nehm en Bremsbahn fet ten (nur bei EC und BM S) Vormontierte Baugruppe in verpackung legen. Nacharbeit 20. Ei ngangsprüfung OK 30. Logistik N OK Verbesserlich? N ein S Ja R Kappe Spiegelfuss Fett Gelenkedichtung Schraube ( 3x) 99 /1. K ont rolle N O K S O K 97/ 1. N OK Ja 98/1. Verbesser lich? Kontrolle R N ein OK 1. S 100 /1. Spiegelfuss und S piegelfussabdeckung zusammenm ont ieren. 2K Gelenkdichtung einrasten, R astkrone des Spiegelfüsses befetten ( aut om. ), Verschraubung 3x. N acharbeit 97/ 2. N OK Ja 98/2. Verbesserlich? Kontrolle R R ohrniet D ruckfeder Sicherungsgleitscheibe G leitscheibe 99/2. Kontrolle NO K S O K N ein O K 1. S 100 /2. R ohr niet, Gleitscheibe, S icherungsgleit scheibe und F eder in V or richtung legen. Vormontierte T räger in V or richtung legen. Vormontierte F ussbaugruppe in Vor richt ung legen und Taumelniet en. K abelverlegung. N acharbeit N OK 197. Ja Verbesserlich? Kontrolle 198. R OK Nein S 1. Verstellantr ieb Kabelsat z Schraube ( 3x) Fusskäppchen 199. Kontrolle S N OK O K 200. Vormontierte Baugruppe w ird aus Tamelnmaschine entnehmen und in Schablone legen. Verstellant rieb und Kabelsat z wird in H and genommen und gest eckt. Verstellantrieb Verschraubung 3x. Kabelposit ionierung. Blinker Stecker auf träger klipsen, Kabel fügen durch Rohrniet und Spiegelfuss. F usskäppchen m ontieren Nacharbeit 297. Kontrolle N OK Verbesserlich? Ja 298. R OK N ein S 1. Glasträgerplatt e Glas Heizungsfolie F ussdichtung Sperrscheibe St ecker gehause (schwarz) St eckergehause (w eis) Gehäuseblende OK 299. Kont rolle N OK S 300. Vorm ont ierte Baugruppe in Schablone legen, Fussdichtung w ird mit Anlage ausdehnen, Fussdichtung auf Kabelsatz f ügen, Positionierung, Steckergehäusemontage 2x, St ecken zum Prüfmaschine. Sperrscheibe in Presserkopf legen, Sperrscheibe pressen. N acharbeit 397. Kontrolle N O K Verbesserlich? Ja 398. R Nacharbeit OK OK Nein S Spi egelglas mo ntage Verkleidung ZB Blinker Schraube (4x) 399. K ont rolle 400. Verkleidung Visualprüfung m achen, Kleberschutzf olie von Blinker entfernen, Blinker in Ver kleidung montieren. Blinker verschrauben 2x. Vorm ontierte verkleidung auf R umpfspiegel set zen und in Schablone legen, dann verschrauben 2x. NOK 457. Kontrolle Verbesserlich? N ein S OK Zeichenerklärung Ja R Prozess Prüfung S R ZB Glas R eibfeder Ausschuss Nacharbeit N OK N acharbeit S 497. N OK Ja 498. V er besserlich? Kontrolle R Nein OK S 1. OK 500. Schutzfolie auf R ahmen anlegen, R eibfeder einklipsen in 499. Kont rolle G last rägerplat te (nur bei EC /BSM ), H eizung kont aktier en und kennzeichnen, EC /BSM Stecker kont akt ier en und kennzeichnen, Spiegelglas auf G lasantrieb klipsen, NOK Schutzfolie abnehmen, Spiegel in EOL einlegen. O K S 510. Elektrische N OK Ja Verbesser lich? endprüfung OK N ein 590. Et ikett ieren S NO K Ja 590. Visual Prüfung Verbesserlich? OK S TOP Nein 600. Polieren, Verpackung S 1. Rückko pplung START Prozess start Teile STOP Prozes s ende Placing of Protective Frame on the Mirror, clicking of the Friction Spring. Connecting and marking of Heating connector. Positioning and marking of Harness. Putting of Glass into Mirror. Placing of Mirrors into End-of-Line-Tester. SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 25

26 4. Problem analysis Databank: all data comes from the system (Visual Inspection, Electrical Test, Monthly Report, Weekly Report, Daily and ShiftPerformance, ) Reference Directories: M / Quality / Internal claim / N / Kaizen / Engineering / Scrap pieces/ week Top 5 scrap in Mercedes assembly line P Painting of Housing Moulding of Housing Painting of Lower Housing Damage of Housing Damage of Lower Housing Total damaging Scrap rate in Mercedes assembly line 5,0% 4,5% 4,0% 3,5% 3,0% 2,5% 2,0% 1,5% 1,0% 0,5% Electrical Test Visual Inspection 0 CW 36 CW37 CW 38 CW 39 CW 40 CW 41 CW 42 CW 43 0,0% CW 36 CW 37 CW 38 CW 39 CW 40 CW 41 CW 42 CW 43 SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 26

27 5. Identification of causes Brainstorming, Priorization Potential causes of the damages during assembly priority Potential causes of the damages during assembly priority one-piece flow system is not fulfilled (2-3 pieces are in a small table xxx polishing cloths are not changed as often as prescribed the cloths on the nest are dirty xx xx drying time is not fulfilled after painting (min 24h) xxx process description is not completed xx scrap housing, lower housing, base cover is getting back to production line xxx parts can be damaged in End of Line tester due to the position of the door pressure arm at actuator is too high xx xx many new employees mentor absence dirty gloves badly assembled mirror is put back against the normal process flow glass is damaging the surface of the housingduring operation & re-assembly xxx xxx xxx xxx xxx small tables are dirty the cloths on the nest are creased training is not effective not interested undisciplined not sufficient knowledge of the assembly process x x x x x x screwing bit scratches the frame after operation after screwing the screwdriver does not go back to starting position xxx xxx too much polishing unnecessary packaging material on the line incorrect material handling x x x SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 27

28 6. Root cause analysis Man Fishbone analysis Machine many new employees parts can be damaged in End of Line tester due to the position of the door small tables are dirty the cloths on the nest are dirty after screwing the screwdriver does not go back to starting position not interested process description is not completed training is not effective pressure arm at actuator is too high polishing cloths are not changed as often as prescribed Screwing bit scratches the frame after operation undisciplined mentor absence not sufficient knowledge of the assembly process badly assembled mirror is put back against the normal process flow too much polishing dirty gloves the cloths on the nest are creased one-piece flow system is not fulfilled drying time is not fulfilled after painting scrap housing, lower housing and base cover is getting back to production line Damage during the assembly process unnecessary packaging material on the line glass is damaging the surface of the housing during operation & re-assembly incorrect material handling Method Process SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 28

29 6. Root cause analysis 1. Which day do the most failure occur? There is not a significant day of week. CW 39 CW M T W 26 TH F M T W TH 24 F 2. Is there any difference between the groups? There is no significant difference between the groups / shifts. Working Group Performance in scrap % 17,22 17,48 15,51 16,59 16,81 15,53 Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 NOT AN OPERATOR ISSUE SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 29

30 6. Root cause analysis Why we have so much scrap? Because sensitive painted parts get damaged. Why sensitive painted parts get damaged? Because of scratches at workstation No. 5. Why are scratches at workstation No. 5.? Because the edge of glass damages the surface. Why the edge of glass damages the surface? Because the protection is not effective. Why the protection is not effective? Because current method is not stable enough! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 30

31 7. Data analysis, ROI (Return of Investment) calculation Number of scrap parts per Month (pcs) Scrap cost ( ) Scrap Cost Failure type April May Jun July Average 1 Day Average 1 Week Average 1 Month Housing damage Lower Housing damage Total Investigation Cost monthly cost Protective Foil to avoid the damage on the parts 862 Protective Tape to avoid the damage in the nest 612 Manual work (Foil fixation on the surface) 528 Mentor 500 monthly cost Protective Frame (400 µ instead 200 µ) to savehousing and Lower Housing 57 Mentor 500 Saving Cost per Month per Month Investigation cost Investigation cost Scrap cost Saving in Saving in Rupee Rupees Rupees Saving in sales % 0,09 % 0,15 % SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 31

32 8. Solution development PDCA Problem Problem root cause Action Resp. damage on Mercedes assembly line on workstation 5. damage on Mercedes assembly line on workstation 5. glass is damaging the surface of the housing during operation & reassembling glass is damaging the surface of the housing during operation & reassembling examine the possibility to use thicher, more deeply covering protective frame at glass assembling process cost calculation (investment, scrap, saving, Return of Investment) Open date Deadline P D C A Status Korpáczy 12. Sept 21. Sept X X X X 100% Meleg 12. Sept 23. Sept X X X X 100% damage on Mercedes assembly line on workstation 5. after screwing the screwdriver does not go back to starting position the triangle at fastening (screw) must be increase by 1-2 cm Korpáczy Szilágyi 12. Sept 27. Sept X X X X 100% damage on Mercedes assembly line on workstation 5. after screwing the tool is able to move back alone and make a damage on the part examine the possibility that the screw be kept in rest position by spring or magnetic Korpáczy Szilágyi 12. Sept 27. Sept X X X X 100% damage on Mercedes assembly line on workstation 5. many new employees to ensure one person as mentor on Mercedes assembly line, who has to teach and control all new workers and and randomly the old workers too Meleg 12. Sept 27. Sept X X X X 100% damage on Mercedes assembly line on workstation 5. base cover can be damaged in cavity to cover the cavity inside with special self adhesive foam Korpáczy 12. Sept 02. Oct X X X 100% SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 32

33 9. Foreseeing the possible resistance Howcanwesolvetheproblem? Protective Foil protects the Housing and Lower Housing from damages! Protective Foil to avoid the damage on the parts 862 Manual work (Foil fixation on the surface) 528 Mentor Barrier: WORKING TIME SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 33

34 9. Foreseeing the possible resistance Protective Tape is covering the nest surface Protective Tapeto avoid the damage in the nest 612 Manual work (Tape fixation on the surface) 528 Mentor Barrier: DURABILITY SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 34

35 10. Trial implementation Pilot implementation of a much stronger Protective Frame to protect the Housing and Lower Housing New Frame is 400 µ thick and 35 mm deep! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 35

36 Is therea solution? Yes, wefoundit! Reduce the lead time! Save money! Easy implemented! Protective Frame (400 µ instead 200 µ) protect Housing and Lower Housing 57 Mentor 500 Protect the parts! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 36

37 11. Regular implementation Assembly process Rework process Protective Frame to protect the Housing and Lower Housing SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 37

38 12. Followupreview& Riskanalysis Time frame: Team: Compass Project name: Reduce damages in Mercedes assembly line Meeting Step Activity Date (Week) IDENTIFICATION OF PROBLEM Pareto, Brainstorming, KJ 2 PROBLEM SELECTION ABC 3 PROBLEM DEFINITION Visual monitoring, Failure mapping, Flow Chart 4 PROBLEM ANALYSIS Databank, Statistical analysis 5 IDENTIFICATION OF CAUSES Brainstorming, Priorisation 6 ROOT CAUSE ANALYSIS Cause& Effect Diagram, 5 Why 7 DATA ANALYSIS Data analysis, ROI calculation 8 SOLUTION DEVELOPMENT PDCA 9 FORESEEING THE POSSIBLE RESISTANCE Pilot Process 10 TRIAL IMPLEMENTATION Trial Process 11 REGULAR IMPLEMENTATION Regular application 12 FOLLOW UP/REVIEW Risk analysis Risk analysis: Reviewed and completed FMEA to determine Risk Priority Number Reviewed and completed Control and the Flow Chart SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 38

39 12. Follow up review& Saving calculation Scrap on Mercedes assembly line (pcs) Target: scrap reduce by 33 % % CW 37 pilot implementation of the new Protective Frame CW 39 regular implementation of the new Protective Frame Achieved: Scrap reduced by 56% SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 39

40 12. Follow up review& Saving calculation 100% Tangible Benefits 80% 60% 40% 20% 100% -33% -56% saving per Month Rupees per Month 0,15% saving in Mercedes sales 0% Before Target Coming from elimination of the damages on Housing and Lower Housing by using the new Protective Frame + 2,4% additional benefit productivity improvement In average 600 Mirrors per Month more are available for the Customer SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 40

41 12. Follow up review& Saving calculation Non-Tangible Benefits I can work faster! -JánosRábai Small things make the biggest difference! - Ferenc Szilágyi The customer has acknowledge my work! - Szabolcs Korpáczy We can do much more as team I have learned that endurance leads to success! -Edit Meleg Management recognisedmy potential! - István Szarka Ideas come by encouraging each other! -Peter Nagy It was hard but worth it! MárióVégh SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 41

42 NextProject Ournextproject is to eliminate the damage on the base cover, too. ZeroDamageinMercedes assembly line! Our mission: We believe this is the RIGHT TIME and the RIGHT PLACE to share and to learn! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 42

43 Köszönöm a figyelmet! SMR_PPT _MSO7_1203_Master SMR is a member of SAMVARDHANA MOTHERSON GROUP 43