2015

kaizen.com
13 Abril 2016
Museu do Oriente
kaizen.com
EXCELÊNCIA NO
SISTEMA DE
MELHORIA
CONTÍNUA
SISTEMA DE MELHORIA CONTÍNUA
Bosch Car Multimedia Portugal , S.A.
Major exporter and employer in Portugal
Braga City Center
Production 2015
0.3 million
Car radios
1.0 million
Navigation systems
0.7 million
Instrumentation systems
0.3 million
Professional systems
Sales 2015
5.4 million
516 million €
Steering Angle Sensors
Associates (as per 01.01.2016)
Other devices (TT / BSH / FP)
1.7 million
2 153
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 3
Bosch Car Multimedia Portugal , S.A.
Certifications for Quality, Health, Safety and Environment
ISO 9001
ISO/TS 16949
ISO 14001
ISO 50001
EMAS III
OHSAS 18001
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 4
Bosch Car Multimedia Portugal , S.A.
Product Portfolio 1990 - 2005
1990
2001
2004
2005
Start of production
for the “Hamburg”
car radio with
cassette mechanism
Start of production of
antennas in Braga
and Vila Real
“Bremen MP 74”, the
first model with
100% mechanical
design from Braga
Start of production of
electronic
controllers for hot
water boilers
1990-1995
1996-2000
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
2001
2002
2003
PRÉMIO KAIZEN LEAN
2015
2004
2005
page 5
Bosch Car Multimedia Portugal , S.A.
Product Portfolio 2007 - 2013
2007
2008
2009
2013
Start of production of
controllers for
Bosch Siemens
household
appliances
Start of production of
communication
systems for trucks
First production line
for steering angle
sensors for ESP
systems
Start of production of
Instrumentation
Systems
Start of production of car
navigation systems
2006
2007
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
2008
2009
2010
PRÉMIO KAIZEN LEAN
2015
2011
2012
2013
page 6
Bosch Car Multimedia Portugal , S.A.
Product Portfolio 2014 - 2016
2014
2015
2016
Start of production of
CCU – Connectivity
Control Unit
Start of production of
Instruments Clusters
with Optical Bonding
Start of production of
2W Instruments
clusters
2014
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
2015
2016
PRÉMIO KAIZEN LEAN
2015
…
page 7
Bosch Car Multimedia Portugal , S.A.
Current Product Portfolio
Navigation Systems
 Smart integration solutions for
entertainment;
Instrumentation
Systems
 Innovative free programmable
instrument cluster;
Next Infotainment Gen
 System integration
 Connectivity
 Navigation;
 Dual-View;;
 TV/Tuner radio;
 Telematics;
 Head-Up-Displays.
 PC HW approach (Intel µP)
 Driver assistance.
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
 Integrated CE solutions
PRÉMIO KAIZEN LEAN
2015
page 8
Bosch Car Multimedia Portugal , S.A.
Current Product Portfolio
Steering Angle Sensor
 Innovative systems and functions
House-hold
Electronics
 Manufacture of complex
Control Units Systems
 Innovative and pioneering
for vehicle safety, dynamics and
electronic controllers for a wide
solutions for room climate and
driver assistance.
variety of different applications.
water boilers.
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 9
Bosch Car Multimedia Portugal , S.A.
Customers in the automotive market
DFM
JAC
GAC
Great Wall
Nanjing
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 10
Bosch Car Multimedia Portugal , S.A.
Key customers in the household appliances market
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 11
BPS (Bosch Production System): System CIP Approach
Cycle of CIP
Performance
Processes
Target
System-CIP
System-CIP
Project
Point-CIP
 Definition of the main
focus
 Implementation of new
standards
 Stabilisation of target conditions
 Elimination of fluctuations
 Business
Requirments
 Priorization of topics
 Derivation of target
conditions (Deliver,
Make, Source)
 Derivation of an
improvement strategy
 Development of new
standards
 Definition of target
conditions for Point-CIP
(break down of the KPI‘s
to improvement level)
Elements:
 Target condition
 Process confirmation with highfrequency on the improvement-KPILevel (ideally event per event)
 Quick reaction to the cause analysis
 Problem solving with verification of
sustainability
 Frequent communication according to
the Point-CIP
Target condition
validation
Daily management
 Implementation of the system inside
the standard
 Reaction to deviations
 Gathering of dates/facts for the next
System-CIP-Cycle
Elements:
 Standard
 Process confirmation adjusted to the
frequency and the KPI-Level
 Quick reaction with the restoration to
standards (Reset)
 Problem solving with the focus on „Reset“
 Frequent communication at the ShopfloorManagement
Definition of duration in order to
verify the stability
Action control limit
Target condition is achieved and
stability has been proven. Point-CIP
becomes
Daily Management (monitoring).
Put the focus on a new problem
Reaction to deviations aims on
quick restoration of the
standards.
Time
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 12
BPS: System-CIP WS
Inputs
Customer requirement
VSM + CIP Flash
Bubble Diagram
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Indicators
Target analysis
KPI Tree Losses
Inputs from DMM (daily
management meeting)
System CIP projects (Status)
BPS Vision 2018
BPS Assessment – targets 2015
.True North
.Lesson learn last revision
PRÉMIO KAIZEN LEAN
2015
page 13
BPS: System-CIP WS
Output
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 14
BPS: System-CIP WS
Team – CIP WS
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 15
BPS: System – CIP Project and Point CIP
Follow up of project by VS Manager
Standards project by project
( Weekly )
Follow-up – KPI / KPR
( Monthly )
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 16
BPS: System – CIP Project and Point CIP
Follow up of project by SC BPS
SC BPS - Agenda for system CIP project and Point CIP meetings
When:
Who:
What:
Team
Available time from team members for the project
First meeting after system CIP
Why this project " Business Case "
Owners
Project target, mainly KPI improvement and monitoring
Description of current situation
Plan for PDCA cycle ( Timeline max. 3 months )
Presentation of the root causes of KPI Monitoring and KPRs outside of target
All meetings until Point CIP
(System CIP projets)
KPI Improvement and Monitoring - Chart evolution and analysis
VS Manager
Owners
Presentation of implemented Standards and approval on the SC BPS
Presentation of the root causes of KPI Monitoring and KPRs outside of target
VS Manager
Deviation of standard detected during process confirmation
During Point CIP
Non fullfilment of target ( KPI stability criteria )
Problem solving sheet for deviation found (PSS)
Teamleader
What are the new standards to achieve the target
Approval of new standard by SC BPS
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 17
BPS: System – CIP Project and Point CIP
Team - SC BPS
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 18
BPS: Point CIP
Elements
Regular Communication
Regular Communication
Registo de participação na Reunião: VS
Duration: From…………until…………….
6
7
Regular date: ……………….
Frequency: Weekly
8
Agenda:
Follow up of KPI and action to cover deviations
VS target condition follow up
9
Results:
Focus the resources on the improvement of the VS
Ensure the successful execution of the target deployment
10
Who is informed?
MOE2, DBE and others VS managers
11
12
Is there a log: OPL
Log distribution list: no
13
What are the consequences of the meeting?
CW
MOE / António Pereira
Place: Gemba (visualization board)
5
DBE / Fernando Teles
Participants:
VS manager
VS team
4
MOE26 / Rui Albuquerque
Objective and purpose:
Follow up of KPI and main improvement activities
3
TEF8 / Daniel Vieira
2
Bosch Production System
Mês: Janeiro
DI
PT
PC
LOG
LOG2
MOE
TEF
TEF1
VSM
CR
VSM
DI
VSM
TT
VSM
CC
DBE1 / Francisco Vieira
Type of meeting: Product family Value Stream
MOE23 / Domingos Vieira
Área:
1
LOG_C_P / Paula Alexandrino
STRUCTURED COMMUNICATION
INFORMATION SHEET
1
2
3
4
5
QMM1
HSE
DBE
DBE1
26-01-2012
SC
Process Confirmation
Fast Reaction System
PSS
Confirmação do Processo
Fast Reaction system
Nº
Escalonamento
Limite de reação
Aplicável ?
Standard
Sim
1
Temperatura do equipamento XPTO = 25º ± 2º
Não
CW 21
19
20
21
22
CW 22
23
26
27
28
CW 23
29
30
2
3
4
CW 24
5
CW 25
CW 26
CW _____
CW _____
Responsável
Data planeada
Data real
Joaquim Engenhoca
23.05.14
23.05.14
6
X
X
X
2
AAAAAAA
3
BBBBBBB
4
Pinos de fixação do PCB no Equipamento XPTO de 0.5 mm ± 2%
X
Follow - up aos desvios ao processo de confirmação
Dia
Nº do
Standard
23
1
Desvio identificado
Causa/motivo do desvio
Temperatura encontrada de 28º
Acão corretiva
Falha do controlador de medida dos limites. Estava mal dimensionado
Dimensionamento através do sistema RPPD3
Pull Cord
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Dias
Se não é feito a confirmação do processo ao novo standard justificar como garantir que não há desvios ao standard
Nº
4
1
Todos os pinos de 0.6 foram retirados do stock. Os pinos novos tem cor azul e branco . Antes vermelho e branco. O encaixe para os novos pinos diferente dos pinos 06.Menor diâmetro não permitindo a colocação do pino antigo.
Department | 29/05/2014 | © Robert Bosch GmbH 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Target Condition
Target Condition
%
.
.. . . . . . . .. . .. . ..
1
2
3
4
1
2
3
4
5
6
7
Standard
inicial
Standard Nº
Sim
x
x
x
x
Não
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Nº de e ve nt os
Nº do evento/ Desvio ao
standard (
) OK e (
NOK
)
Obs. Preencher apenas em caso de standard Nok.
Nº do
Evento
Causa Raiz
NOK
7 10
7
Parafuso do fim do curso solto
Acão corretiva
Trocar parafuso 2,5 para 3.5 e lacar
Resp.
Data
Planeada
Data
Implement.
J.Engenhoca
22.05.14
22.05.14
PSS
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
Nº do Evento
Nº PSS
Data de abertura
Data de fecho
Nº de dias desde a
abertura até ao fecho
10
1
25.05.14
30.05.14
5
Confirmação da eficácia da PSS
Chefe de linha
Chefe de secção
PRÉMIO KAIZEN LEAN
2015
page 19
BPS: DMM
Daily follow-up of the KPI Monitoring
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 20
BPS: Savings
First revision 2015
473 543 € / monthly
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 21
Prémio kaizen Lean - 2015
13 de Abril de 2016
Thank you for your attention
EXCELÊNCIA NO SISTEMA DE MELHORIA CONTÍNUA
PRÉMIO KAIZEN LEAN
2015
page 22