presentation by: nkumbuzi ben-mazwi 02 july 2018 · 2018-08-03 · presentation by: nkumbuzi...
TRANSCRIPT
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“TOGETHER MOVING THE GAUTENG CITY REGION FORWARD”
AIDC Kaizen promotion and development
African Kaizen Annual Conference
Presentation by:Nkumbuzi Ben-Mazwi
02 July 2018
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2
Who is the AIDC
• Established in 2001 by Industry & Gov.
• Established as an industry support centre with a
focus on automotive sector.
• The AIDC is an implementation agency of
provincial government
• Approx. 150 staff across multiple sites
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33
SA AUTOMOTIVE
Landscape
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4
Johannesburg
Where are the
Original
Equipment
Manufacturers,
OEMs,
Located
in
South
Africa ?
Lesotho
UitenhageEast London
Durban
Port
Elizabeth
Rosslyn
Original Equipment Manufacturer
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5
Auto Sector at a Glance
Source: AIEC, Econometrix, NAAMSA/Lightstone Auto,NAACAM, OICA, SARS
Indicator Performance
2015 2016
ConsumerPrice Index (CPI) 4,6% 6,3%
South Africa’sGrossDomestic Product (GDP) (current prices) R4 049,8 billion R4 337,0 billion
Broader automotive industry contribution to GDP 7,5% 7,4%
Vehicle and componentproduction as % of South Africa’smanufacturingoutput 33,5% 33,0%
Average monthlyemploymentby vehicle manufacturers 31 260 30 953
Automotivecomponentsector employment 82 100 82 000
Capital expenditure– vehicle manufacturers R6,6 billion R6,4 billion
Capital expenditure– componentsector R2,8 billion R2,6 billion
Total South Africannew vehicle sales 617 648 units 547 406 units
Total South Africanvehicle production 616 082 units 599 004 units
South Africa’svehicle production as % of Africa’svehicle production 64% 58,5%
South Africa’sglobal vehicle production ranking 22nd 22nd
South Africa’sglobal vehicle production marketshare 0,68% 0,63%
Vehicle ownership ratio per 1 000 persons 180 180
Total automotive export earnings R151,5 billion R171,1 billion
Automotiveexport value as % of total South Africanexport value 14,6% 15,6%
Numberof export destinations 140 154
Numberof export destinations with export values more than doubling year-on-year 30 52
Topautomotive country export destination in rand value terms Germany Germany
Total South Africanvehicle exports 333 847 units 344 859 units
Value of vehicle exports R101,9 billion R118,1 billion
Topvehicle export destination in volume terms UK UK
Value of automotivecomponent exports R49,6 billion R53,0 billion
Topautomotive export componentcategory in rand value terms Catalytic converters Catalytic converters
Topautomotive trading partner in rand value terms Germany Germany
Topautomotive trading region in rand value terms EU EU
Topcountry of origin for total automotive imports in rand value terms Germany Germany
Topcountry of origin forvehicle imports India India
Source: AIEC, Econometrix, NAAMSA/Lightstone Auto, NAACAM, OICA, SARS
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6
Component Assembly and Manufacturing
Vehicle Assembly
(OEMs)
Retail Sector
Total Number of Companies
480
Tier 1 (Supply directly to OEMS)
120
Tier 2 -3 (Supply to Tier 1 and 2)
360
Total Number of Jobs 82 790
Total Number of OEM’S 22
Total number of Passenger and Light Commercial OEM’s
7
Total Number of Jobs 29 700
Total Number of Retail Companies
7 500
Total Number of Service and Repairs Companies
1 898
Total number of Fuel and garage stations
4 551
Total Number of Dealerships
1 768
Total Number of Tyre Dealers
1 506
SA Automotive Value Chain
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7
KAIZEN
AIDC APPROACH
and
AWARD SYSTEM
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AIDC Kaizen standardized process flow
Activity 0 1 2 3 4 5 6 7 8 9 10 11 12 13
Train the trainer
Management
and Union Awareness
Company
wide mass awareness
Value Stream
Map
External and
Internal Responsibility
matrix
Orientation
Management
strategy meeting
Internal Project
review meeting (AIDC)
Model Area 1
(A-Team)
Company
MRM
Model Area 2
(B-Team)
Model Area 3
(A-Team)
Rollout
strategy meeting
Customer
satisfaction feedback
report
Implementing
committee monthly project
review meeting
Monthly
champion review meeting
Senior
Project Manager and
Champion Project
Customer
satisfaction feedback
report
Customer
satisfaction feedback
report
Customer
satisfaction feedback
report
SWOT
Implementing committee
Internal Project
review meeting (AIDC)
Internal Project
review meeting (AIDC)
Internal Project
review meeting (AIDC)
Senior
Project Manager and
Champion Project
Senior
Project Manager and
Champion Project
Senior
Project Manager and
Champion Project
Company
MRM
Company
MRM
Company
MRM
Company
MRM
Company
MRM
Company
MRM
Company
MRM
Company
MRM
Model Area 4
(B-Team)
Company
MRM
Management commitment, company and union awareness, monthly review meetings, Recognition, TEI (Total Employee Involvement)
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Representatives :
1. JMAC
2. AIM (Host Supplier)
3. The Dti
4. AIDC
5. Suppliers
6. NAACAM
7. ASCCI
8. NAAMSA
KAIZEN INDUSTRY BUY IN
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KAIZEN FACILITATORS TRAINING
All facilitators from different companies
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Kaizen Kick-off event
TPM Kick-off at Autoliv12 December 2014
*Attended by NAACAM director
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AWARD SYSTEM-SCORING CRITERIA
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AWARD SYSTEM PANEL OF JUDGES
Representatives – NAACAM, OEM- Mercedes Benz and Lean Institute Africa
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KEY NOTE SPEAKERS
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AWARD – OVERALLWINNER
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AWARD - OPERATOR SHOP-FLOOR WINNER
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KEY Stakeholder JICA and LIA (Partnerships)
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Award Winners
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AWARD SYSTEM-PROCESS
1. Continuous annual recognition and motivation of companies on Kaizen promotion
2. Selection and invitation of companies to participate and show case CI3. Industry and Government support and participation4. Standardised presentations and proccesses for the award5. Scoring Criteria must be defined6. Independent panel of Judges and very knowledgeable on Kaizen7. Key support stakeholders and partners participation8. Define categories of awards eg. Operator/employee and Management
separation9. Recognition and rewarding of excellent achievements by Senior Industry
and Government representatives
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AIDC Annual Best Practice Tours
8 Different manufacturing companies attended best practice tour* fully paid for by industry
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JICA EXPERT TRAINERS AND APPROACH
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22 22
① Identify Abnormality
・ Decide Standard and Criteria
② Detect Abnormality
③ Stop Production by Abnormality
④ Inform Abnormality Immediately
⑤ Quick Countermeasures
⑥ Recurrence Prevention
Abnormality Management Process
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23
19 M/c in total
Supplier
Re
ceiv
ing
Pro
cess
Supplier
Supplier
Ra
w M
ate
ria
l Sto
re
Wir
e B
ulk
Sto
ck
500
379
Bojan
SLV
Se
als
Crimp Toyota
Smiths
Bosal
Test
Final Test
Final Test
Process test
Packing
Packing
Packing
Toyota
Smiths
Bosal
Raw
Material
Power Cable
Layout Board
Sleeving
Stores Bored
Line Leader
Pro
du
ctio
n
Bo
ard
Module
KIT
TIN
G
EDT
Portal
Delivery Schedule
Production Planner
Production Planner
Supervisor
Purchasing Stagnation –Batch Production
Back & Fourth Movement
Too many operators – Line imbalance
MIFD
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PROBLEMS IDENTIFIED FROM MIFD
2. Too many operators – Line imbalance
3. Too much movement
1. Stagnation and bulk production at each stage – total 50 at each stage
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25
OPERATION TIME
25
Operation Time Calculation
Start Finish Total Hrs
Shift Time (Hours) 7:00 15:30 8:30
= 8,5 hours
Shift Time (min) 510 min
Less: Lunch = 30 min
Less: Tea Break = 20 min
Less: MDWT = 10 min
Total Available Time 450 min
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Reprogramming of Robot and forging machine
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STANDARDISED WORK CHART (BEFORE)
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STANDARDISED WORK COMBINATION TABLE (BEFORE)
Above Takt
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STANDARDISED WORK CHART (AFTER)
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28.5% CT improvement CT now within TAKT TIME
STANDARDISED WORK COMBINATION TABLE (AFTER)
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Challenges
• Commitment and leadership from an organisation leader, management and Government.
• Resources availability in terms of budget, qualified and experienced personnel.
• Kaizen Sustainability and Total Employee Involvement (TEI)
• National Government involvement and Prioritisation of Kaizen at Policy level
31
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32
THANK YOU
Nkumbuzi Ben-Mazwi
AIDC
Making excellence an attitude