kalwa plant lean implementation v2.1

8/12/2019 Kalwa Plant Lean Implementation v2.1

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Pa'e

1(0 )*e+ui!e Summary and Company Ba+,'round -

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1*0 2e!tie !mmary and Company Ba5gro!nd

Briefly3 in his +ase &e 'limpse on 4al&a Plane5Siemens in 6ndia &hi+h impro!e iself from a

radiional or'ani7aion o lean mana'emen sru+ure(

8he firs Siemens &or, shop sared on May 1 s3 19 in a small pla+e on Mumai &ih 10

employees and &ih !ery simple euipmen;s( 8heir main usiness is fi*in' dama'ed s&i+h

oards and oher fari+aion produ+er 3medium !ola'e indoor and oudoor !a+uum +ir+ui rea,ers =MC> produ+er 3 'as

insulaed s&i+her =M25G6S>produ+er in suppor of he main +ompany 3 u also hey impro!ed

heir posiion in he mar,e 3 no& he +ompany has fa+ories in Mumai 3 $asi, 3 Cal+ua

3Auran'aad and Goa 3 /000 employees and 11 sales offi+es3 -00 dealers ( Furhermore heir

+ompany is se+ond Siemens fa+ories ouside of Germany afer Bra7il ran+h(

Siemens impro!e is produ+s in / se+ions: 15indusry 25ener'y -5healh+are /5+onsumer

produ+s in 6ndia and all of he &orld and our +ase +ompany manufa+ured lo& !ariey and hi'h

!ariey produ+s &hi+h elon' o po&er disriuion se'men3 ener'y di!ision( Siemens

Company in 6ndia +ompeed &ih ABB3 Are!a3 S+hneider ele+ri+s on he oher hand 4al&a

produ+s e*pored o Ban'ladesh3 Sri ?an,a3 $epal3 Bhuan3 Maldi!es3 @man3 .aar and e+(

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6n 20093 0 o per+en of 8he S&i+hoard Fa+ory =SB> area allo+aed o manufa+urin'

panels =M1> and 6#CBs =MC> and remain spa+e remains for manufa+urin' @#CB =MC> and M2

produ+s( 8his +ompany had /00 personnel =lue and &hie +ollar> and employees &or,ed in 2

&or,in' shifs and one addiional shif =if ne+essary>(

Man!at!re yle order planning and logisti:

6niially3 he firs se+ion &ihin M1 di!ision &ere S@) =sales order en'ineerin'>3 desi'n

manufa+urin'3 pro+ess plannin'3 esin' and ualiy pa+,a'e and dispa+h +ommer+ial3

in+omin' inspe+ion and sores( ?o+al +usomers ordered o he re'ional sales eam and

mar,ein' eam fo+used on e*por orders( )!ery order ha ransferred o he S@) mar,ed and

enered o he fa+ory( All he orders mus passed &o sa'es: 15esi'n and en'ineerin' sa'e 3 25

order plannin' and e*e+uion sa'e( Afer an order re+ei!ed y mar,ein' se+ion3 hen S)@

prepared an en'ineerin' dra&in' &ih +ooperaion &ih sales +ollea'ues and +usomer =o +o!er

+usomer needs>3 hese dra&in' prepaid in 2 sa'e A and B3 in sa'e A: hey ha!e all info e*+ep

&irin' dia'ram &hi+h +ompleed in se+ion B( Afer passin' hese &o le!els hey sen heir

dra&in' o he +usomer o appro!e and hen send i o he manufa+urin'( urin' hese

pro+esses S)@ +onsuled hem o a!oid any non5sandard +usomer reuiremen if all he le!el

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passed +orre+ly he do+umens &ere passed o he manufa+urin' deparmen( 8e+hni+al @rder

Pro+essin' deparmen =8@P> re+ei!ed orders and re+orded i in o he produ+ion plannin'

daaase a++ordin' o heir imes hen deli!ery +ommiee ried o esimaed he deli!ery dae o

he +usomer( )!ery order needed &o ype of ra& maerials =euipmens> :15ele+ri+al 3 25

me+hani+al 3he op saff &roe he ne+essary euipmens in a lis ha +alled =B@M> ill of

maerials lis ( 8he B@M sen y enerprise resour+e plannin' sof&are =)P> o he maerial

plannin' deparmen3 me+hani+al euipmens &ere e*ised inside of he +ompany and ele+ri+al

needed o order o he supplier(

8hen pro+uremen +y+le sared ne* euipmens release o he shop a++ordin' o he

reuiremen(

8he e*is manufa+urin' sysem had many error3 &ase and ineffi+ien+ies in shop floor and

lo'isi+ =hey &ased lon' ime and !aluale ra& maerials and someimes he manufa+ured

panels &ased e+ause of &ea, layou desi'n> 3 on he oher hand on 200 +usomer demands

in+reased around % per+en and mana'ers need o enhan+e heir manufa+urin' pro+ess

effi+ien+y o redu+e heir +oss and respond sooner o he +usomer demand (in @+oer 200

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Siemens AG sen a leer re'ardin' he implemenaion of lean mana'emen in 4al&a +ompany

and menioned hey ea'erness o impro!e 4al&a fa+ory li,e he oher ran+hes durin' he

&orld ( 8hey e*pe+ed his implemenaion &ill enhan+e +ompany;s +apa+iy o riple durin' fi!e

or si* years(

"ean management implementation steps:

8he lean mana'emen eam !isied Siemens sie in 8ur,ey &hi+h mana'ed in lean mana'emen

mehods hen +onsulan added o he eam memers3 one of he mos imporan duies for

mana'ers and eam memer is o +larify ho& mu+h his implemenaion is !ial for he +ompany

o hold is mar,e share and all he personnel had a +rii+al role o a+hie!e his 'oal3 hus

mana'ers sared he ?ean mana'emen pro+ess &ih rain sormin' amon' all he +ompany

se+ions 3 hey as,ed &hi+h poins ma,e &ase durin' produ+ion pro+ess 8hey &aned o ,no&

and eliminae any &ase of ime and ra& maerial durin' produ+ion line( Do&e!er3 +han'in' he

&or,in' mehods &hi+h many person &or, &ih i for many years has some resenmen amon'

differen 'roups(

he lean eam de+ided o di!ide heir +han'es o : 15layou 25suppor sysem -5!endor

mana'emen /5+ulural +han'es 3 &hi+h hese +han'es +aused o impro!e he 4al&a +ompany

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effi+ien+y( ?ean eam had meein' &ih personnel of se+ions ha had more errors afer lean

implemenaion3 eam memers ried o find ou prolems and see, o sol!e he issue(

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7*0 8!estion 1

.as iemens %al&a plant een eetie in a;ieing lean implementation had in+reased y appro*imaely y /0 per +en

-( or,er produ+i!iy had in+reased appro*imaely y -0 per +en

Siemens 4al&a plan should furher refine and impro!e he impro!ed pro+essesIfun+ions or o

in+lude oher pro+essesIfun+ions &hi+h no par of he ori'inal s+ope o e par of he lean

implemenaion( Siemens 4al&a plan should loo, ino implemenin' lean o he remainin'

pro+essesIfun+ions as sho&n elo&:

1( esi'n deparmen pro+essesIfun+ions

2( )n'ineerin' deparmen pro+essesIfun+ions

-( #endor and supplier manufa+urin' pro+essesIfun+ions

8he approa+h ao!e +omine &ih he adheren+e o lean prin+iples and lean seps should ensure

lean implemenaion is susainale(

3*0 8!estion 7

.o& &as t;e organi=ations ;ange proess managed as a eam o

impro!e heir or'ani7aion +ulure 3 for feelin' eam elon'in' he de+ided o a,e -0 min for

heir pray and spor a+i!iy daily(

4*0 8!estion 3

W;at resistane did %;ande5ar ae in implementing t;e ;ange and &;y

.o& &as t;e lean implementation instit!tionali=ed in t;e ne& set?!p de+ided o implemen lean manufa+urin' in he

4al&a fa+ory3 fe& iniial seps &ere a,en o ensure a proper foundaion in erms of ,no&led'e

and undersandin' of lean manufa+urin' is firs uild in he 4al&a fa+ory( Mr(Ge&ald3 'loal

head for spearheadin' lean pro


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eam &ih Mr( 4hande,ar as he pro Chan'es in #endor

Mana'emen

d) Culural Chan'es(

%ey +tiities

8he moniorin' 4P6s &eredefined(

A moniorin' eam &as formed

o do+umen3 analyses and

repor on hese 4P6s(


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Figure 1: Implementation plan of lean manufacturing.

As menioned in uesion one3 lean manufa+urin' y prin+iple is he eliminaion of &ase or

non5!alue added &or,s( As su+h3 Mr(4hande,ar and he lean eam reali7ed ha hey need o

resru+ure oh he layou and he pro+ess iself o eliminae non5!alue added &or,s( aher han

lindly doin' he implemenaion pro+ess3 he eam firs did pro+ess mappin' for he e*isin'

pro+ess o undersand ho& i &or,s( 6n he pro+ess mappin' sa'e3 he lean eam held dis+ussion

&ih he enire deparmen in he !alue +hain re'ardin' heir pro+ess flo&( 8he ou+ome of his

a+i!iy &as pro+ess flo& +har( $e*3 he lean eam analy7ed he pro+ess flo& +har o idenify

all non5!alue added in he flo&( A rainsormin' session &as done &ih all he relaed personal

o de+ide he +han'es ha need o e made o ma,e he pro+ess more effi+ien( A his sa'e he

lean eam also held meein's &ih all he employees o e*plain &ha lean manufa+urin' is all

aou and &hy i is imporan for hem o adop lean in heir &or,pla+e( 8his &as an imporan

a+ion y he lean eam as here &ere si'ns of resenmen and s,epi+ism amon' he employees(

From he firs &o sa'es of he implemenaion plan3 +han'es ha are reuired o

eliminae &ase &ere idenified( 8he +han'es are as elo&: 5

"ayo!t C;anges

For he layou +han'es3 he assemly line +on+ep &as adoped( Assemly lines &ih

&or,saions &ere formed( 8he ime per &or,saion &as fi*ed and heir &or, +onen &as

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ashoards &ere inrodu+ed a he e'innin' of ea+h assemly line( Any issues in he produ+ion

line &ill e hi'hli'h in he oard &ih name of he relaed personal( Meein's &ill e held on

daily ases o o!ersee all he issues( 8he dashoard also &ill display daily ou of ea+h assemly

line o sho& pro'ress in ea+h line( Apar from ha s,ill assessmen of he employees and op

mana'emen &ere also done +oninuously o idenify s,ill 'aps and appropriae rainin' are

arran'ed(

C;ange in @endor Management*

8he main idea here is o ha!e pars a!ailale a he ri'h ime and ualiy( #endor &ill ha!e o

supply ea+h order a++ordin'ly raher ha supplyin' in a+h( Be+ause of some diffi+ul fa+ed

&ih he !endors3 shor erm and lon' erm plans &ere made( ?on' erm plans are o implemen

lean prin+iple a he !endor;s end( As for shor erm plans are he implemenaion of pull

philosophy of he lean sysem &herey !endors &ill manufa+ure maerial in ul, u deli!er i

o fa+ory as needed y he line( 8his is o redu+e sora'e and in!enory spa+e in he fa+ory(

C!lt!ral C;anges

A+i!iies su+h as on monhly ases( 8o summary3 &e

+an say se!eral ,ey a+ions ha!e een a,en o insiuionali7e he lean implemenaion in hene& se5up of he 4al&a Fa+ory(

i> Before implemenaion pro+ess &as sared3 a proper foundaion &as uil in he +ompany

y edu+ain' he op mana'emen on he lean prin+iples(

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ii> A sound implemenaion plan &as made y he lean eam y firs3 analy7in' he e*isin'

pro+ess o idenify ineffi+ien+ies( 8hen deermine &ays and means o impro!e hem(

iii> 8he lean eam +oninued o edu+ae all employees from saff le!el o &or,er le!el o

ensure all of hem undersood he lean prin+iples(

i!> Proper moniorin' &as done o ,no& he effe+i!eness of all he +han'es made(

!> Mr(4hande,ar and his eam also +oninuously +ome up &ih +reai!e soluions for

prolem su+h as resenmen and &or,er issues(

W;at more does %;ande5ar need to do so t;at t;e ;anges are not reersed

i) eg!lar +!diting*

e'ular audiin' in he &or, floor is imporan o ensure ha all he +han'es in erms of pro+ess

flo& and &or, sandards are follo&ed a++ordin'ly( e'ular audi mus also e done o all relaed

supplier and !endors o ensure heir +omplian+e &ih he lean prin+iples(

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A*0 eerene

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kalwa plant lean implementation v2.1

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