8 STEPS IN THE LEAN TRANSFORMATION

◂ 2 | 23 ▸

1º Current Value Stream Mapping (VSM) and systematic analysis

2º Workload balancing, flow improvement based on the takt time

3º Standardization of the process steps

4º Use of a real-time computerized visual management system

5º Use of Kanban in the points of use

· Kits design and preparation, moving to point of use

· Design and replenishment of production supplies

6º Setting up of a supply chain with all the suppliers

· Six Sigma incoming quality, test benches

7º Engineering redesign beyond the known limits (VSMF)

· Break of the known molds or broad outlines

8º Achievement of a total transformation to the continuous one-piece flow

◂ 3 | 23 ▸

PROFESSIONAL EXPERIENCE

IN THE AERONAUTICAL INDUSTRY

PRODUCTION PROCESS

BOEING 737 ASSEMBLY PLANT

◂ 4 | 23 ▸

Boeing 737 plane final assembly plant in Renton, Washington

Use of Lean tactics and tools from a traditional stationary assembly line to a moving assembly line

Total change of the purchase procedure from procurement to Kanban replenishment

Delivery time reduction from 8-15 days to 3 days

From ISO quality to Six Sigma quality

◂ 5 | 23 ▸

BOEING 737 ASSEMBLY PLANT VALUE STREAM MAPPING 1996

◂ 6 | 23 ▸

BOEING 737 ASSEMBLY PLANT VALUE STREAM MAPPING 2004

APACHE LONGBOW ASSEMBLY PLANT

◂ 7 | 23 ▸

Apache Longbow helicopter final assembly plant in Mesa, Arizona

Use of Lean tactics and tools to move from a stationary assembly line to a pulse moving line

Major reductions in build hours

Significant increases in build rate

◂ 8 | 23 ▸

PROFESSIONAL EXPERIENCE

IN THE AERONAUTICAL INDUSTRY

SUPPLY CHAIN AND SUPPLIER ANALYSIS

SUPPLY CHAIN IMPROVEMENT

◂ 9 | 23 ▸

Machining and manufacturing division Outsourcing

Propulsion systems Outsourcing

Flight stabilizers Turnkey

Interior systems Turnkey

Landing gear Outsourcing

Fuselage Turnkey

Flight control Outsourcing

Suppliers of production supplies Turnkey

PARETO SUPPLIER ANALYSIS BY VALUE

◂ 10 | 23 ▸

Top 14 suppliers (26% out of 53 suppliers) account for 83% of total inventory value

Fictitious data

for didactic purpose

82.4%

79.9%

77.0%

73.9%70.4%

66.8%63.3%

58.1%52.8%

46.2%39.5%

32.1%

22.9%11.6%

€ 0.00

€ 50,000.00

€ 100,000.00

€ 150,000.00

€ 200,000.00

€ 250,000.00

€ 300,000.00

€ 350,000.00

Mag

na D

onne

lly E

lect

roni

cs

JCI C

reut

zwal

d

Dr S

chne

ider

Sidle

r Gm

bH &

Co.

KG

Nor

ther

n Aut

omot

iv S

yste

ms

Dr S

chne

ider

OVP

E2V

John

son

Con

trols R

oth

SA

Lear

Aut

om. E

EDS P

olan

d SP Z

LEAR

cor

pora

tion

JCI A

rend

al

JCI W

uppe

rtal

Nor

ther

n Eng

raving

Cor

p.

Eissm

ann

Autom

otive

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

SUPPLIER GEOGRAPHICAL DISTRIBUTION

◂ 11 | 23 ▸

6 SUPPLIERS UK - IRELAND

5 LOCAL

SUPPLIERS

6 SUPPLIERS SOUTH REGION

18 SUPPLIERS SWEDEN

12 SUPPLIERS

NORTHERN GERMANY

5 SUPPLIERS FAR EAST

Fictitious data for didactic purpose

◂ 12 | 23 ▸

PROFESSIONAL EXPERIENCE

IN THE AERONAUTICAL INDUSTRY

COMPUTER SYSTEM PARAMETER ANALYSIS

EXAMPLE PROJECT

◂ 13 | 23 ▸

Forecasted OH inventory

with changes 6 months OH inventory

historical data

Area of opportunity

Level

of daily usage = 50.2

Fictitious data

for didactic purpose

ON HAND INVENTORY PROJECTION

◂ 14 | 23 ▸

1 shipment per week

Complete pallets 2 safety days Average inventory = 400 units

2 shipments per week

Only full layers 1 safety day

Average inventory = 150 units

WITH CURRENT PARAMETERS WITH PROPOSED PARAMETERS

PARAMETER CHECKING

◂ 15 | 23 ▸

Inventory in warehouse analysis

Minimum safety stock analysis

· Raw materials

· Sub-assemblies

· Production supplies

Suppliers delivery time

Deliveries logistics and frequency

QUALITY DEVIATION

◂ 16 | 23 ▸

Lower limit

Upper limit

Abnormal situation warning risk

Fictitious data

for didactic purpose

Achievement of 99%-101% purity in production

PRODUCTION PERFORMANCE

◂ 17 | 23 ▸

Forecast (C1) vs. actual (C2) production performance

Theoretical

performance

Actual performance

Fictitious data

for didactic purpose

Forecast

performance

Added

reprocessing

REAL-TIME CONTINUOUS IMPROVEMENT

Process improvement requires the backing of an advanced IT tool

Our control and continuous improvement integrated system incorporates:

· 50 indicators for Lean Management

· 10 OLAP cubes for Lean Management

· Alert and programmable action system associated to the indicators for Lean Management

◂ 18 | 23 ▸

PROJECTS FOR THE AERONAUTICAL INDUSTRY

Coaching for management

Conduction of change management teams or high performance teams

Interim management for the implementation of multidisciplinary projects

Analysis of functional and operational needs in information systems

Pull systems through balance scorecards

Management for EFQM implementation

Development of sectoral competitiveness-oriented projects

◂ 19 | 23 ▸

PROJECT METHODOLOGY

I. DIAGNOSIS

BY INDICATORS

Prioritization of needs. Choice of solutions Standardized monitoring tool

II. IMPROVEMENT

PROJECT

Work team

Value Stream Mapping. Identification of problems. Solutions Action plan: objectives, measures, means, indicators, etc. (1 week)

III. AUDIT

AND FOLLOW-UPS

Verification of the compliance of the action plan

Measurement of the indicators of needs for improvement (once a week during 3 months)

IV. CONTINUOUS

IMPROVEMENT

Conclusions and final report with measures New objectives for improvement Continuous improvement system

standardized, objective, easy to apply and to measure

◂ 20 | 23 ▸

RELIABLE EXPERTISE IN THE AERONAUTICS INDUSTRY

◂ 21 | 23 ▸

All our projects are led by our Project Director Juan J. Rodríguez:

Lean Sensei with extensive international experience in Total Lean System implementation Management Strategic Leadership Training Six Sigma Black Belt Value Analysis – Value Engineering Certified Trainer by Save International Institute Expert in implementation of information systems such as MRP, MRPII and ERP systems

Electrical Engineering – Durango University Business Administration – University of Texas One of the most prominent Hispanics in the USA (Who's Who Among Hispanic Americans, Library of Congress 1993)

Sound professional background in the aeronautic industry: Collins Transmission Systems Div., General Electric Aerospace, Boeing, NASA, US Department of Defense, Rolls Royce Jet Engine Div., etc.

SUCCESS STORIES

PROJECTS FOR PRIVATE COMPANIES IN SPAIN

PROJECTS FOR PUBLIC BODIES

OTHER PROJECTS

◂ 22 | 23 ▸

TEACHING PROJECTS

CONTACT US

HEADQUARTERS

Avda. Juan Carlos I, 55. Edif. JC1. Planta 16

30100 Murcia. Spain. EU

T +34 968 235337

WEBSITE

www.aquiline.es

COMMUNITY

www.aquiline.es/twitter www.aquiline.es/facebook

www.aquiline.es/google+

www.aquiline.es/linkedin

www.aquiline.es/xing

www.aquiline.es/viadeo

www.aquiline.es/flickr www.aquiline.es/youtube

◂ 23 | 23 ▸

E-MAIL

clients@aquiline.es