GROWTH : ANOTHER SOURCE OF WASTE · Lean manufacturing is a systematic method for the elimination...
Transcript of GROWTH : ANOTHER SOURCE OF WASTE · Lean manufacturing is a systematic method for the elimination...
GROWTH : ANOTHER SOURCE OF WASTE
Marios Mitrosilis
Group Manufacturing Excellence ManagerKleemann Lifts
➢ Who is Kleemann?➢ How we became your 1st Choice in Lifts➢ Case study: Lean Manufacturing implementation
in the Electronics Factory
WHO IS KLEEMANN?
Manufacturing
We manufacture in Greece, China and Serbia
Prestigious Projects
Prestigious Projects
HOW WE BECAME YOUR 1ST CHOICE IN LIFTS
19831
9
9
0
1992
1995
1996
1998
1999
Growth: Main Factory Development
New Factories:• 1999: Doors Factory• 2001 : Electronics Factory• 2002 : Cabins Factory• 2004 : Logistics Center in
Athens• 2005 : Kleemann Liftovi
(Serbia)• 2011 : Kleemann China
2011 : Testing Tower (Greece)
• 61 meters high
• 3rd highest privately
owned testing tower
in Europe
• Developed lifts up to
6m/s
2019 : Testing Tower (China)
• 100 meters high
• To develop lifts >10m/s
Resulting Layout
Current Layout
CASE STUDY: LEAN MANUFACTURING IMPLEMENTATION IN THE ELECTRONICS FACTORY
Presenting work done by:
George Mitsas, Program manager "Lean Manufacturing Implementation“ at KLEEMANN
Chrysavgi Danaktsi, Lean Manufacturing Implementation at KLEEMANN
Lean manufacturing is a systematic method for the elimination of waste within a manufacturing system.
Lean also takes into account waste created through overburden and waste created through unevenness in work loads .
Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for.
Lean is centered on making obvious what adds value by reducing everything else.
Lean Manufacturing
Lean
Manufacturing
Goals : ➢ Controller assembly positions redesign➢ Precabling lean flow assembly line➢ Operating Panels lean flow assembly line➢ Design of a new Testing Area➢ Kanban implementation
Value Stream Mapping : Before
• Order Throughput: 9,2 days
• Production replanning has
heavy influence in
productivity
• Need of space for storing
semifinished parts
• Many transfers of parts to
different positions
Value Stream Mapping : After
• Order Throughput: 1,5 days
• Faster production planning
absorbs fluctuation in
demand
• 33,61% less space required
• Less transfers of
semifinished parts
Layout
AfterBefore
Before After % Improvement
Production [m2] 416 400 3,85%
Materials [m2] 698 369 47,13%
Semifinished Parts [m2] 112 45 59,82%
Total 1226 814 33,61%
Results
Results
• Order Throughput: from 9,2 to 1,5 days. (83,70% improvement)
• Fluctuation in demand is not transferred to production
• 33,61% less space required
• Less stock thanks to Kanban
• Less paperwork
• Simple visual inspection of production area
• Improved quality
• Improved productivity
• Continuous Improvement Culture
THANK YOU!