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An introduction to T&D FSSC
Lean Service
Marcus Pinnegar & Laetitia Simpson
London, March 18th
2 2Areva T&D FSSC Lean Service –– Copyright Areva T&D
Agenda
� Introduction
� Lean Foundation
� Methodology
� Continuous Improvement
� Results & Key Success Factors
3 3Areva T&D FSSC Lean Service –– Copyright Areva T&D
Introduction to Areva & Areva T&D
� Operating Income*
€397 million
� Employees*
25 248
� Sales revenue*
€4.33 billion
2/3 Nuclear
1/3 Transmission & Distribution
*2007 figures
� Countries
100
4 4Areva T&D FSSC Lean Service –– Copyright Areva T&D
Introduction to Areva T&D FSSC
� Total costs
€12 millions
� Employees
400
� Market Share
70%
of 250 T&D Units
� Locations
10
�Organisation – Northern Europe example
�AP invoices
0.8 million
M.Pinnegar
North Europe
FSSC Manager
RegionalFinance Director
J.Lambert
Global FSSC
Director
CFO
VP Finance Systems &
process
�Main activities in all FSSC
Accounts payables
T&E
Accounts receivables – cash application
General Ledger, Fixed Assets
Treasury
+ in some FSSC : C&Collection, Reporting
5 5Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Foundation - Commitment from Management
6 6Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Foundation - Lean Culture Training
« Forget any pre-conceived ideas."
Shigeo Shindo
7 7Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Service Roadshow 06-07
NOV 06NOV 06OCT 06OCT 06
DEC 06DEC 06
JUL 06JUL 06
OCT 06OCT 06
OCT 06OCT 06
AUG 06AUG 06
SEP 06SEP 06
NOV 06NOV 06
OCT 06OCT 06
Lean Service Training + workshop achieved
JAN 07JAN 07
JUL 07JUL 07
FEB 07FEB 07
JUL 07JUL 07
8 8Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Foundation – Genba, Genbutsu, Genjitsu
“Genshi Genbutsu”
“Go & See for yourself”
Kiichiro Toyoda
“If we can’t measure it, we can’t improve it”
Lord Kelvin
9 9Areva T&D FSSC Lean Service –– Copyright Areva T&D
Project ManagerProject Manager
Sourcing ManagerSourcing Manager
Sourcing ManagerSourcing Manager
SourcingSourcing
Sourcing SecretarySourcing Secretary
Project Site ManagerProject Site Manager
Value Stream Mapping – Example 1/2
SupplierSupplierSupplier
Issue Good Receipt Inspection Report
Receive Material Check Quality
ReceptionistReceptionist Receive mail if courrier
“receipt date”
GR in SAP
Parking
Prepare invoice covering letter
Check as per dispatch instruction
Collect Invoice & dispatch
OKYes
No
Sort Invoice by day
Prepare & Print Excel sheet of invoices
Sign
Check & Sign
Approve & Sign
21Days
Av
era
ge
Le
ad
tim
e
5 days
AP Accounts Executive AP Accounts Executive
10
days
Print Cheque & attach with docPrint Cheque & attach with doc
Check documents Check documents
Post in SAP & write posting N°
Post in SAP & write posting N°
Check weekly in SAP the payments due
Check weekly in SAP the payments due
Clear payment in SAPClear payment in SAP
Write Cheque N˚Write Cheque N˚
Create Cheque in SAPCreate Cheque in SAP
Sign PA onlySign PA only
Unit FSSCUnit FSSC
Unit FCUnit FC
Senior ManagerSenior Manager
Sign PA onlySign PA only
Sign ChequeSign Cheque
Sign ChequeSign Cheque
6
days
PA
First Map & Measure basedon interviews in office,
Internal Control Assessement, data extracts
from system …
10 10Areva T&D FSSC Lean Service –– Copyright Areva T&D
Project ManagerProject Manager
Sourcing ManagerSourcing Manager
Sourcing ManagerSourcing Manager
SourcingSourcing
Sourcing SecretarySourcing Secretary
Project Site ManagerProject Site Manager
Value Stream Mapping – Example 1/2
SupplierSupplierSupplier
Issue Good Receipt Inspection Report
Receive Material Check Quality
ReceptionistReceptionist Receive mail if courrier
“receipt date”
GR in SAP
Parking
Prepare invoice covering letter
Check as per dispatch instruction
Collect Invoice & dispatch
OKYes
No
Sort Invoice by day
Prepare & Print Excel sheet of invoices
Sign
Check & Sign
Approve & Sign
21Days
Av
era
ge
Le
ad
tim
e
5 days
AP Accounts Executive AP Accounts Executive
10
days
Print Cheque & attach with docPrint Cheque & attach with doc
Check documents Check documents
Post in SAP & write posting N°
Post in SAP & write posting N°
Check weekly in SAP the payments due
Check weekly in SAP the payments due
Clear payment in SAPClear payment in SAP
Write Cheque N˚Write Cheque N˚
Create Cheque in SAPCreate Cheque in SAP
Sign PA onlySign PA only
Unit FSSCUnit FSSC
Unit FCUnit FC
Senior ManagerSenior Manager
Sign PA onlySign PA only
Sign ChequeSign Cheque
Sign ChequeSign Cheque
6
days
PA
Eliminateregister
Make GR as soon as possible
Removeparking
Reduce thesecontrol to min.⇒Target 100% PO invoices – sign PO
⇒ Control of remaining non PO
invoices & invoiceswith variance vs PO
Removethis control
Eliminateregister
Removethis list
GR preparation
by Reception area
Quick
wins
11 11Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Foundation - Standard
“Where there is no Standard there can be no Kaizen”
Taiichi Ohno
Standard
D
PA
C
12 12Areva T&D FSSC Lean Service –– Copyright Areva T&D
5S – Standardize offices
» SEIRI / SORT – classify between necessary and unnecessary
» SEITON / STORE – keep needed items in the right place for easy retrieval
» SEISO / SHINE – keep your office clean
» SEIKETSU / STANDARDIZE – Set as a standard the first 3S
» SHITSUKE / SUSTAIN – Make a habit of maintainingestablished procedures
» SEIRI / SORT – classify between necessary and unnecessary
» SEITON / STORE – keep needed items in the right place for easy retrieval
» SEISO / SHINE – keep your office clean
» SEIKETSU / STANDARDIZE – Set as a standard the first 3S
» SHITSUKE / SUSTAIN – Make a habit of maintainingestablished procedures
� Full Standardization for more flexibility =>efficiency
Archiving
Work station
Cabinets
Mailing room
Why 5S is key ?
� Employee Satisfaction EHS,
Friendly environment
� Visual Management Visibility of non standard
Dashboards
14 14Areva T&D FSSC Lean Service –– Copyright Areva T&D
Continuous improvementsKaizen
“A journey of a thousand miles start with a single step”
Confucius
15 15Areva T&D FSSC Lean Service –– Copyright Areva T&D
Continuous improvement Methodology
KaizenWorkshop
Satisfaction Survey
FSSCMetrics
LeanServiceActions
16 16Areva T&D FSSC Lean Service –– Copyright Areva T&D
Lean Service Temple
STANDARD : VALUE STREAM MAPPING, 5SSTANDARD : VALUE STREAM MAPPING, 5S
FMEA
MULTISKILLS MATRIX
FMEA
MULTISKILLS MATRIX
POKA
YOKE
VISUAL CONTROL
POKA
YOKE
VISUAL CONTROL
LEAN
SERVICE
LEAN
SERVICE
KAIZENKAIZEN
MANAGEMENT COMMITMENTMANAGEMENT COMMITMENT
SAN GEN SHUGI / TEAM WORKSAN GEN SHUGI / TEAM WORK
On Time DeliveryOn Time Delivery 0 Defect0 Defect
LEAN CULTURELEAN CULTURE
17 17Areva T&D FSSC Lean Service –– Copyright Areva T&D
What about Results ?FSSC China Pilot
7 500
4 d.
12 d.
80%
AFTER
2 500
AP+T&E
documents / p. /
year
12 d.
T&E claims
payment Lead time
Average nb of days
22 d.
AP Posting Leadtime
Average nb of days
43%
Office Lay out
% staff satisfied
BEFORE
18 18Areva T&D FSSC Lean Service –– Copyright Areva T&D
What about resources needed to be successful?T&D experience
»Lean Service Roadshow
»1 FTE
»Lean Service Roadshow
»1 FTE
07/06 07/07 07/08
»FSSC China Pilot
»1 FTE Lean facilitator
»FSSC China Pilot
»1 FTE Lean facilitator
»FSSC India Pilot
»1 FTE Lean facilitator
»FSSC India Pilot
»1 FTE Lean facilitator
Lean Service deploymentLean Service deployment
Kick
Off
19 19Areva T&D FSSC Lean Service –– Copyright Areva T&D
What could have been done differently ?
»FSSC China Pilot»FSSC China Pilot
»FSSC India Pilot»FSSC India Pilot
12 months
Kick
Off
»Lean Service Roadshow
»Lean Service Roadshow
6 months
Lean Service deploymentLean Service deployment
20 20Areva T&D FSSC Lean Service –– Copyright Areva T&D
Key Success factors
� Identify « burning platforms » and be opportunistic
� Don’t try to build the ultimate programme
� Make it a « workfloor » tool not a HQ programme
� Identify quick wins and standardize fast
� Sell once first success come
� Step by step improve
21 21Areva T&D FSSC Lean Service –– Copyright Areva T&D
Conclusion
“Improvement has no limit”
Standard
D
PA
C