boc strategic meeting presentation 2010
TRANSCRIPT
Managing Complexity of Managing Complexity of Process Process ChangesChangesBy Christine SchmetzBy Christine Schmetz
Quality System Services ManagerQuality System Services Manager
1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
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2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…
11--1 About Emerson 1 About Emerson
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A diversified technology company with
US$ 20.9B of sales worldwide in FY 09.
11--1 About Emerson 1 About Emerson
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129,000 employees 250 manufacturing locations worldwide –
165 located outside the United States.
1-1 About Emerson Structure
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55
Europe USA Asia
Process Management
Appliances & Tools
IndustrialAutomation
NetworkPower
5 Financial Segments
of Emerson
• Supermarkets
• Restaurants• Pharmaceutical industry• Air driers• Milk cooling• Industrial process cooling
• Chillers • Rooftop systems• Commercial and Light Commercial Heat Pumps
• Self-contained systems• Water coolers
11--1 Emerson Climate Technologies 1 Emerson Climate Technologies -- Products Products & Markets& Markets11--1 Emerson Climate Technologies 1 Emerson Climate Technologies -- Products Products & Markets& Markets
REFRIGERATIONREFRIGERATIONCOMMERCIAL COMFORTCOMMERCIAL COMFORT
• Chillers • Rooftop systems• Commercial and Light Commercial Heat Pumps
• Self-contained systems• Water coolers
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Air Conditioning and Heat
Pumps for residential
applications
• Trailers and commercial distribution trucks• Trains and busses• Sea containers
RESIDENTIAL COMFORTRESIDENTIAL COMFORT
TRANSPORTATIONTRANSPORTATION
Heating, Ventilation, Air Conditioning and Refrigeration solutions for residential, industrial and commercial applications.
•Air Conditioning and
Heat Pumps for
residential applications
• Trailers and commercial distribution trucks• Trains and busses• Sea containers
11--1 Emerson 1 Emerson Climate Technologies Products ManufacturingClimate Technologies Products Manufacturing11--1 Emerson 1 Emerson Climate Technologies Products ManufacturingClimate Technologies Products Manufacturing
Welkenraedt, Belgium
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NORTH AMERICA:
� Brantford, Ontario (Canada)
� Sidney, Ohio (4)
� Hartselle, Alabama
� Natchitoches, Louisiana
� Ava, Missouri
� Lebanon, Missouri
� Rushville, Indiana
� Reynosa, Mexico
� Guadalajara, Mexico
EUROPE:
� Cookstown, Northern Ireland
� Welkenraedt, Belgium
� Mikulov, Czech Republic
� Kolín, Czech Republic (Alco)
� Pieve d´Alpago, Italy (Dixell)
ASIA:
� Suzhou, China
� Shenyang, China
� Karad, India
� Atit, India
� Rayong, Thailand
� Dubai, UAE
11--1 About our1 About our Manufacturing Manufacturing Location Location in Belgium.in Belgium.11--1 About our1 About our Manufacturing Manufacturing Location Location in Belgium.in Belgium.
� Biggest Manufacturinglocation in Europe
� +/- 500 Employees
� Max. capacity :250.000 compressors
� Machining and Assembly
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� Machining and AssemblyProcesses.
1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 9
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…
11--2 About 2 About our Productsour Products11--2 About 2 About our Productsour Products
3 Product Families
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SUMMIT 7.5-15Hp
SPECTER7.5-15Hp
LCS 20-40Hp
11--2 About 2 About our our Machining & Assembly ProcessesMachining & Assembly Processes11--2 About 2 About our our Machining & Assembly ProcessesMachining & Assembly Processes
1 Machining area – 2 Zones (Turning & Milling)
Turning
Milling
2 Main Assembly Lines - 3 Product Families–
Merging into 1 for the Final Process
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LCS / SPECT
ER
LSH
DS
Summit Ass.
Specter /LCS Ass. Final Test
Pack.
Painting
1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 12
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…
11--3 Adonis 3 Adonis as as ourour central central ProcessProcess ModellingModelling PlatformPlatform
40 Main Processes65 Sub Processes
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PRODUCTION PROCESS FLOWADMINISTRATIVE PROCESSES
3 Assembly LinesMachining Area
11--3 Mapping Manufacturing Processes 3 Mapping Manufacturing Processes –– Why ?Why ?11--3 Mapping Manufacturing Processes 3 Mapping Manufacturing Processes –– Why ?Why ?
Innovation :
Quick Respond to Market Needs and Trends
=> Introduction of new Products on existing lines
Customer Orientation :
Professional way to communicate with customers / auditors about
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Professional way to communicate with customers / auditors about control plan, process flow, changes made on process….
Productivity :
Continuous Rebalancing of the line to increase Productivity(automation of operation, new equipment, move operation…).
11--3 Mapping Manufacturing Processes 3 Mapping Manufacturing Processes –– Why ?Why ?11--3 Mapping Manufacturing Processes 3 Mapping Manufacturing Processes –– Why ?Why ?
Quality :
Ensure Flexibility and Continuous Improvement of the Control Plan :
1- Increase / Decrease control frequency :
- Justified by problems encountered,
- By equipment capability,
- FMEA risk analysis
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- FMEA risk analysis
2- Add / Suppress Control
3- Change Ownership of Controls
Demand Driven :
Ensure efficient training of new operators (peak season)
Ensure flexibility of operators on the line (ability to work on variousworkstations)
11--3 3 ManufacturingManufacturing ProcessesProcesses -- SpecificitiesSpecificities
- Many Product variations on same Assembly Line.
-1 Model per Manufacturing Process (including various products)
LCS
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11--3 3 ManufacturingManufacturing ProcessesProcesses -- SpecificitiesSpecificities
Work-, Control-, Checking-, Mastering Operations
Work Op.
Control Op.
Unique ID N°
Color Codes
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Control Op.
Checking Op.
Mastering Op.
11--3 Link 3 Link between Operation and Controlsbetween Operation and Controls11--3 Link 3 Link between Operation and Controlsbetween Operation and Controls
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Automatic Link to the related Control Operations
11--3 Key Figures3 Key Figures
3 Assembly Lines Machining Area
84 Workstations 23 Workstations
230 Work Operations 78 Work Operations - 232 Sub Op.
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230 Work Operations 78 Work Operations - 232 Sub Op.
214 Control Operations 587 Control Operations
65 Checking Operations 52 Checking Operations
125 Equipements 60 Equipements
600 Documents 350 Documents
11--3 Elements linked to an Operation3 Elements linked to an Operation11--3 Elements linked to an Operation3 Elements linked to an Operation
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1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
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2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…
2. Different Types of Changes2. Different Types of Changes2. Different Types of Changes2. Different Types of Changes
Keep processes up too date
« Daily changes » - Short Term – Versions / Status
Current model is being updated to reflect short-term changes
Versus
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Integrate new product, new cell…
« Major change » - Long Term - Variants
Daily Changes must be integrated on a regular basis on the model +
the model serves as basis for the implementation of major mid- or long termchanges.
22--1 „Daily Changes“ 1 „Daily Changes“ –– Key FiguresKey Figures22--1 „Daily Changes“ 1 „Daily Changes“ –– Key FiguresKey Figures
Ca. 400 Changes / year
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Ca. 250 Changes / year
22--1 „Daily Changes“ 1 „Daily Changes“ –– Key DriversKey Drivers22--1 „Daily Changes“ 1 „Daily Changes“ –– Key DriversKey Drivers
Control plan (control frequency, add/suppress….)
Operations (line rebalancing => reallocate operations & operationcontent)
Suppress / Add machining sub operations
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Introduction of new tooling, equipement,…
…
=> Communication, Reactivity, Integration and Traceability
22--1 „Daily Changes“ 1 „Daily Changes“ -- Get InformationGet Information22--1 „Daily Changes“ 1 „Daily Changes“ -- Get InformationGet Information
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22--1 „Daily Changes“ 1 „Daily Changes“ -- Prepare Change ImplementationPrepare Change Implementation22--1 „Daily Changes“ 1 „Daily Changes“ -- Prepare Change ImplementationPrepare Change Implementation
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-Increment Version of current model - « Save as » in the DRAFT Folder (move ref.)-
-Change Status in « DRAFT »
22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes
-Identify Impact of Changes
-Search
-Object references
-Related Controls
-….
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-….
22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes
- Implement Changes on process flow and related elements :
-Documentation
-SOEs
-Equipment => EQM software
-Control Plan
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22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“ 1 „Daily Changes“ -- Implement ChangesImplement Changes
- Track changes in History
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22--1 „Daily Changes“ 1 „Daily Changes“ -- ApproveApprove22--1 „Daily Changes“ 1 „Daily Changes“ -- ApproveApprove
- Publish DRAFT Model in HTML
-- Send approval mail (votting buttons) and get « Approve » or « Comments »
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22--1 „Daily Changes“ 1 „Daily Changes“ -- PublishPublish22--1 „Daily Changes“ 1 „Daily Changes“ -- PublishPublish
- Change status of current model in « Archived »
- Drag current model in folder ARCHIVED – ADL export on server
- Change status of draft model in « Released »
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- Change status of draft model in « Released »
- Drag in folder RELEASED
- Inform users per e-mail of new version (+ change history)
22--2 Major Changes2 Major Changes22--2 Major Changes2 Major Changes
Introduction of a new product on existing Assembly Line (ex. REF Summit)
⇒Existing process as a basis :
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⇒ to assess required investments and changes
⇒ to develop control plan
⇒ to establish or review documentation…
22--2 Major Changes 2 Major Changes –– Current situationCurrent situation22--2 Major Changes 2 Major Changes –– Current situationCurrent situation
Changes related to the new « product » are :
- Integrated in the current model – Red Agregation.
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22--2 Major Changes 2 Major Changes –– Current situationCurrent situation22--2 Major Changes 2 Major Changes –– Current situationCurrent situation
New product is added in the product model.
-New product is added in the new / existing operations.
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22--2 Major Changes 2 Major Changes –– Current situationCurrent situation22--2 Major Changes 2 Major Changes –– Current situationCurrent situation
By clicking on the new
Product in the product model,
Point at operations referring
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Point at operations referring
To this new product.
22--2 Major Changes 2 Major Changes –– Current situationCurrent situation22--2 Major Changes 2 Major Changes –– Current situationCurrent situation
- Red Agregations will dissapear when new product is released.
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1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 37
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Challenge: Issues to be solved…
3. Challenges3. Challenges3. Challenges3. Challenges
2 (or more) models being updated in parallel :
-To reflect short term changes.
-To assess / prepare new product implementation.
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-SYNCHRONIZATION….
Thank You For Your Attention ! Thank You For Your Attention !
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