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Professional Engineering
Dromone’s Lean Journey Presentation
April 2014
Philip Gillic
Business System Manager
Professional Engineering
Product Portfolio
Agriculture Tractor Pick Up Hitch 58% Revenue
Construction Excavator Quick Coupler 42% Revenue
Professional Engineering
OEM Business
55% Total Revenue
OED Agriculture Distributor
22% Total Revenue
Customer Portfolio
Construction Distributor
23% Total Revenue
Professional Engineering
2015 Company Goals
Professionalise all levels of the Dromone organisation
Grow sales profitably to meet 2015 plan
Protect existing business:
Quality, Service, Competitiveness
Exceed industry expectations in:
Quality, Safety and Environmental protection
Implement Right First Time principles
Develop robust supply chain through supplier management
Professional Engineering
Operations
Excellence
Right First Time.
Cost reduction through-
efficiency improvement.
Throughput Time.
Customer
Management
Voice of the Customer.
Sales Margin.
Key Account Management.
Supplier
Management
Cost Reduction.
Right First Time.
Reduced Inventory.
Engineering
Design
New Product Introduction.
Right First Time.
Continuous Professional-
Development (CPD).
What we have to achieve
Professional Engineering
Phase 1:
Analysis
Map Current State & understand major
issues
Provide core skills training in Problem
Solving, Project Management & Lean
Create High Level Future State Vision
& Roadmap
Phase 2:
Stabilisation
Eliminate 8 basic wastes & deploy Standard Work
Introduce RFT principles & effective
NCR Process
Improve NPI Process & deploy PFMEA
Improve performance of
process constraints & start to reduce
batch sizes
Phase 3:
Process Design
Develop detailed Future State Map
Continue to stabilise, deploy standard work,
reduce batch sizes, & load level
Modify the Planning process to produce products on EPEX
Cycles
Phase 4:
Introduction
Phase 5:
Improvement
Implement layout
changes, Kanban &
Pull Systems
Deploy Andon and
Jidoka principles to
deal with abnormal
conditions
Kick off
improvement
programme with
major suppliers
Introduce Heijunka
Boards
Reduce EPEX Cycle
to collapse
throughput times
Professional Engineering
Feeling the Pain
Burning Platform
Value Stream Mapping
Urgency
Constraint Identification Data Flow
Product Flow
Throughput Time
Order fulfilment 2.2 months
The activity ratio was 3.4%
Constraint Identification
CNC drilling OEE was 29%
Batch processing prevailed
Local functional efficiency
Professional Engineering
Believing In Lean
Importance of believing
Senior management & key person confidence
Clear goals
Test and learn in safe environment
Learning and Practice
Zero Defect Work Shop
Quick Change Over workshop
Lead Time Reduction Work Shop
Professional Engineering
Clear Lean Thinking
Importance of Stable Processes
Critical thinking skills
Structure and common language
Tools and skills
New Product Introduction Practices
KT Problem Solving training
Customer Communication using KT
tools
KT Project Management Training
Professional Engineering
Islands of Excellence
Early success is critical
Illustration of what “Good” looks like
Confidence in the process
Early champion and advocates
Assembly Area Project
Physical changes in the area
Team living the beliefs and behaviours
Team Leader Champion: Mick Lynch
Quality Problems Originating In Final Assembly
2013
0
2
4
6
8
10
12
14
16
JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC
Series1 Linear (Series1)
Standard Time Tracking across Product Family
900
1162
13201380
840702 720
1800
2949
400
90150200
0
500
1000
1500
2000
2500
3000
3500
1 2 3 4 5 6 7 8 9 10 11 12
Measurement Number
Std
. T
ime
in
se
co
nd
s
Large Pushback (A)
Large Pushback (B)
Small Pushback
Mousetrap
Roller
Vertical
Acc Assy
Direct Pack Acc
K80 Ball
Professional Engineering
Knocking Down Barriers
New Problems and Challenges
Challenges strengthen Lean journey
Vocal and Passive Resistance
Physical issues: batch size reduction
Dealing with challenges
“Call to arms”
Motivated middle management
New Process Engineering Team 0
500
1000
1500
2000
2500
3000
3500
4000
Ho
urs
Wk 25 Wk 33 Wk37 Wk 39 Wk 41 Wk 43
Welding Constraint Arrears KPI
Professional Engineering
Celebrating Success
Inspire Transformation
Motivation for the team
Reinforce success
Internal company success
Secure Employment & Personal
Development
New business contracts
JCB, Volvo Construction
Equipment, Agco
Professional Engineering
Celebrating Success
External recognition
Agco Supplier Quality Award 2012
Engineers Ireland CPD employer of the year
National Award 2013
Regional Company of the Year Award 2013
National Lean Conference Participation, Dublin
Castle, Ireland
IMC 29 Key Note Speaker on Dromone Lean
Systems Project 2013
Professional Engineering
Summary
Start of the Lean Journey for Dromone
Big step in the right direction
Feeling the pain and believing in Lean
Clear thinking and knocking down barriers
Celebrating success
Positive business and customer impact
Professional Engineering
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