EOQ MNB Hat Szigma és Lean Szakbizottsági ülése Üdvözlet a Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. nevében Budapest, 2014 szeptember 23. Száraz Kálmán Termék minőség mérnökség vezető
Tartalom: Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. bemutatása KPS azaz Knorr Production System és LEAN kompetenciák TPM és DNC Zero deffect filozófia 5dF és Fabrik des Jahres 2013 Andon rendszer A JIDOKA újra-értelmezése Auditok, Tanúsítványok. Kérdések és válaszok
Answers for a World of Mobility Every day, more than 1 billion people put their trust in systems from Knorr-Bremse The 3
History of KBU History and Milestones of the Production Plant (old factory) Purchase and Foundation Opening Ceremony Dispatching Station Halle XU Freight car shop Dec June 1995 1996 Start of Production Nov 1996 Dec Jan 1999 2000 new Warehouse Dec 2002 new Paintshop July 2004 Aug. 2005 DV-BUD May 2007 4
History of KBU History and Milestones of Production Plant (new factory) Construction of the Building starts Building completed, STC start Nov 2008 Decision to build the new factory Feb 2009 Dec20 09 DV-BUD start at the new factory Mar 2010 Jul 2010 New factory opening after transfer 5
History of KBU New factory KNORR- BREMSE HUNGARY (KBU) Facts & Figures Size: - Plot size approx. 90.000 m² - Factory approx. 26.000 m² - Offices/Social areas approx. 6.600 m² - Further expansion area approx. 11.000 m² Employees: - Cca. 1150 employees Turnrate: 15 will be achieved in 2012 vs. 2014 6
Main figures Development of Turnover* and Headcount Headcount Turnover * internal KB-Group Turnover (meur) 7
Main KPI s Turnover share by product groups (sales data from 2013) CoC Bogie Equipment (BE) (80% Turnover) CoC Brake Control (BC) (10% Turnover) Repair, service, etc. (2% Turnover) CoC Air Supply (AS) (8% Turnover)
Main figures Headcount KBU total headcount - actual 9
KBU Products and Engineering Products CoC BE for Loco s Tread Brake Units Compact Caliper for Axle mounted Disc - RZS BR185 10
KBU Products and Engineering Products CoC BE for High Speed Trains Compact Caliper Units WZK Conventional Caliper New Pendolino 11
KBU Products and Engineering Products of CoC BE for Metros Tread Brake Units Metro Shanghai 12
KBU Products and Engineering Products CoC BE for Freight Cars BG-Cylinder Slack-adjuster 13
KBU Products and Engineering Main Products Segment BC Components for Freight Cars eighing valve LH angle cock Freight/Passenger change over device Brake hose coupling 14
KBU Products and Engineering Main Products Segment BC Components for Passenger Cars Emergency box Valves Panel equipment Brake couplings Change over device LH angle cock Indicator 15
KBU Products and Engineering CoC AS Air Dryer tanks of drying chambers bracket, houses, piston valve covers, magnetic valve Only components for Compressors crankcases cylinders, cylinder heads piston rods, flanges air inlets 16
KBU Products and Engineering Selection of References our Products ICN Bombardier Switzerland Flirt MÁV Stadler Hungary Metro Toronto ROTEM Canada Shinkansen JR-East Japan Pendolino Alstom Italy, Finland KZ4A - Pass. Loco KZ8A Freight. Loco Alstom Kazahstan ICE Siemens Germany Metro Caracas Alstom Venezuela Desiro Siemens UK, Germany 17
KBU Products and Engineering Research & Development Engineering CoC BE and CoC BC Engineering CoC Bogie Equipment Engineering CoC Brake Contol (Pneumatics) Technical Analysis Finite Element Method Brake application to railway bogies Design and development of brake caliper units and tread brake units Warranty engineering and design to cost Release tests and serial endurance tests Design and development pneumatical components and brake panels Modularization of valve systems Know how transfer integrated brake control systems Release tests and serial endurance tests Finite element modeling of brake units and components Strength calculations of models on the basis of ANSYS or HYPERWORKS platform Stress assessment Preparing strain gauge test of brake units 18
KBU Products and Engineering Brake Control Panels Tailor-made piped Brake Control Panels with Standard - Components high Project-Flexibility short Development-Time proven Design System-Test prior Installation fast Installation low Maintenance Costs 19
KBU Products and Engineering Research & Development Electronics Software Development (safety relevant and others) Development and verification of safety relevant sofware up to SIL3 (Safety Integrity Level 3) Development of brake control functions, such as Wheel Slide Protection Driver assistance systems System Qualification and Diagnosis Design, development, test and release of complete brake systems Vehicle dynamic simulations and system tests up-to 550km/h Vehicle tests with remote data logging Complete diagnostic of onboard systems Hardware Development Development and qualification of embedded electronic hardware Obsolescence management Simulation of failure probability, and timing issues 20
Manufacturing competencies Knorr Production System (KPS) = Continously Improved Processes Productivity / Efficiency / Flexibility Quality Machining processes (internal and external) Surface treatment technology Assembly methods Logistic methods / SCE 5dF Approach Product quality - Zero Defect approach 21
Production competencies Machining competency Applied KPS methods TPM Andon, status visualization Flexibility matrix 5S CNC Centres for Milling & Drilling CNC-Centres Turning OEE SMED Pull with synchronization 22
Quality Control for machined and sourced parts FAI inspection by QC Optical scanner Laser scanner First-off Measuring by QC Equipments of Q-Department Spectroscope several Hardness and Shore Hardness Tester Spring Force Tester Profile-Projector Contour graph Coating Thickness Tester Roughness Tester Magnetic Crack Detector Salt Spray Chamber Conditioning Cabinet (-70 C +170 C ) Laser scanner White stripe (optical) scanner Self Inspection by Operators 5 x Wenzel LH87 X=800, Y=1500, Z=700 accuracy : U3 = 2,5µ+L/450 1 x Wenzel LH87 fix head X=800, Y=1500, Z=700 accuracy : U3 = 1,7µ+L/350 several 2D measuring machines more than 15000 gauges 23
Production competencies Surface Treatment (STC) competency Applied KPS methods Pull with synchronization Continous flow Waste elimination 5S Visualization Shop floor KPI 24
Production competencies Assembling competency Applied KPS methods Pull-Principle One-Piece-Flow PFMEA Poka-Yoke CAA Flexibility matrix 5S KANBAN Visualisation Standard work TPM 25
Competence of Machining - Total Productive Maintenance (TPM) All CNC machines are in DNC online Info of machine failure via SMS and email download of CNC programs m/c status visualization planning of work orders analysis of utilzation working planned TPM no work breakdown wait for new series set up quality control 1st-off 26
Feedback Loop Strategy and advanced methods Zero Defect approach Operation Source Inspection using Poka Yoke BEST Mistake Defect Successive Inspection: Checked and controlled by the next person, operation Defect Found at next process stage Defect found at end of line Judgement Inspection Defect found within factory Judgement Inspection Defect found at customer WORST 27
Logistic challange / 5-day-Factory The 5-Day-Factory Hungary (5 days throughput time) 1 2 3 The 8 principles Transparent information processes to improve communication Integration of design into the plant for short and direct feedback InSupply ensures a material availability close to 100% Orders Machining Orders Assembly 2 days 1.5 days 1.5 days 7 4 5 6 Cells for complete parts machining incorporate all relevant technologies Integration of the Shared Technology Centre (STC) One-piece-flow assemblies applying standard work procedures 3 4 Source InSupply External Machining Machining 5 6 Shared Technology Centre Assembly and Test Deliver 7 8 Heijunka planning to level the production by quantity and sequence Value stream based layout for short and transparent material flows 1 2 8 28 28
The business challenge and our solution Awards for the 5dF approach and implementation BEST VALUE STREAM proc elog@istics 2013 Fabrik des Jahres 2013 29
Robust Processes KBU Automatic Stop / Andon system ANDON case Start of issue Shift leader, Process controller decides within 5 minutes if they need escalation or not. ANDON 1. LEVEL +15 minutes ANDON 2. LEVEL +10 minutes ANDON 3. LEVEL Engineers (SQA, design, assy proc. ) STC shift leader Team leaders (SQA design, assy proc ) STC leader deputy Assy process team leader Department leader Quality Manager, Design Leader STC Leader Technology leader 30
JIDOKA Hogyan is értelmezzük?! - AUTONOM(ous oper)ation - 1 1. A Termelés feladata 1.) Konstrukciós követelmények teljesítése 2.) Csökkenteni (Szabályozni) a változékonyságot 2. A termelés kulcs pontjai = JIDOKA AUTONOM(ous oper)ation Folyamat gazda garantálja a termékminőséget a saját folyamatában A folyamat gazda fel van vértezve a jó-nem megfelelő közötti döntés jogkörével Csak minőségileg 100%-ban igazolt termék küldhető tovább a következő folyamatlépésre Jidoka Jidoka Jidoka Jidoka Source InSupply External Machining Machining Shared Technology Centre Assembly and Test Deliver Jidoka 31
JIDOKA Hogyan is értelmezzük?! - AUTONOM(ous oper)ation - 2 3. Hogyan vezessük be a JIDOKA -t minden termék-életciklus fázisra JIDOKA a JIDOKA a JIDOKA a Tervezési fázisban Folyamat fejlesztési fázisban Termelési fázisban = = = Jó műszaki rajz és követelmény Jó folyamat kialakítás Jó folyamat ellenőrzés 1.) Konstrukció, ami tiltja a rossz összeszerelést Design to Assy 2.) Könnyen végrehajtható, Könnyen érthető a Jó és Nem-megfelelő termék állapot (OK / NG) 3.) Kis termelés irányítási leterhelés (pl. standard alkatrészek egységesítése) 1.) Magas folyamatképesség 2.) Könnyen végrehajtható, Könnyen érthető a jó és Nem-megfelelő termék állapot (OK / NG) 3.) Megállás nem-megfelelő termék esetén 4.) Tiszta jelölése a karbantartott készülék és eszköz állapotnak 1.) Könnyen végrehajtható, Könnyen érthető a Jó és Nem-megfelelő termék állapot (OK / NG) 2.) Standard * munkafolyamat, ami garantálja a jó minőséget követéskor 3.) Terv és erőforrások a megfelelő karbantartáshoz Jidoka Jidoka Jidoka Jidoka 32
JIDOKA Hogyan is értelmezzük?! - AUTONOM(ous oper)ation - 3 4. Standardizálás (= Normálizált állapot): ~Csökkentett változékonyság, Problémákra összpontosított figyelem~ 1.) Könnyen végrehajtható 2.) Könnyen érthető Ha az operátor nem képes követni a Standard munkafolyamatot 3.) Könnyen követhető Nem szabályozott állapot 4.) Rendszeresen ellenőrzött és frissített ( legfontosabb) Munkautasítás - részlet Munkautasítás lebontás (JIB) - részlet 33
JIDOKA Hogyan is értelmezzük?! - AUTONOM(ous oper)ation - 4 5. Hogyan oktassuk ki a Standard munkafolyamatot? Munkautasítás lebontás (JIB) - részlet Ki végzi 1. darab 2. darab 3. darab Oktató 4. darab 5. darab 6. darab Betanuló 34
Audits per year 16 ISO14001 ISO14001 Nr of Audits ISO14001 ISO14001 14 ISO9001 ISO9001 ISO9001 ISO9001 12 10 10 8 6 4 4 2 2 0 0 TSI TSI TSI 2001 2004 2009 Future? 2001 2004 2009 2014
Strategy and advanced methods KBU - Winner of the National Quality Award 2005 36
Selection of successfully passed Audits, Certificates 1997 Jan. DB-Audit, Q1-Level 1998 Dec. ISO 9001 Audit 1999 Dec. ISO 14001 Environment Audit 2000 Jan. DIN 6700 Welding Audit 2000 Mar. Customer Audits 2003 Nov. REX implementation, combined audit 2005 Oct. Hungarian Quality Award 2006 Jun. TSI audit for freight car parts 2009 Febr. IRIS audit OHSAS18001:2007 2012 Dec. Bonding DIN6701-2 2013 Jun. IT Security ISO 20000-1 2013 Dec. Fabric des Jahres Best Values Stream 37
Kérdések és Válaszok?!?!
Köszönöm a figyelmüket! Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. Helsinki út 105 Budapest, Magyarország H-1238 Száraz Kálmán Termék Minőség Mérnökség Vezető www.knorr-bremse.com Phone: +36 1 2894 216 Fax: +36 1 2894 261 Mobile: +36 70 414 96 13 E-mail: kalman.szaraz @knorr-bremse.com