Contenu connexe Similaire à From push to pull in IT by Faurecia (20) Plus de Institut Lean France (20) From push to pull in IT by Faurecia1. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
From push to pull in IT:
learning to create value for users
is not a long, quiet river
2. Copyright © Institut Lean France 2013
Faurecia overview
2012 key figures
94,000 employees
320 sites
34 countries
Group revenues: €17.4 billion
30 R&D centers
5,500 R&D engineers and technicians
460 patents filed in 2012
Annual R&D investment: €943 million
5.4% of revenues
2
3 & 4 October, 2013
Paris, France
6th largest automotive equipment supplier
(2012 revenues €bn)
1. Bosch
2. Denso
3. Continental
4. Magna
5. Aisin Seiki
6. Johnson Controls
6.
8. Hyundai
9. ZF
10. Yasaki
11. Lear
12. Delphi
13. TRW
14. BASF
15. Valeo
16. Sumitomo
17. Toyota Boshoku
18. JTEKT
19. Hitachi
20. Cummins
17.4
N°6
°
worldwide
worldwide
equipment
equipment
supplier
supplier
3. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Operational Excellence
driven by the Faurecia
Excellence System
Renault Global Quality award
Ford Silver World Excellence Award
General Motors Supplier Quality Excellence Award
9 Awards for Chinese sites, including
Dongfeng Nissan Excellent Quality Performance
Quality : steady PPM rate at 18
3
4. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Back in 2006
Low cost IT, poor customer focus
Limited investments on
value added projects
15%
Impact
of new projects
Patchwork of systems
Seating
Interior
Components
BM 400
Mfg
Pro
85 % Running existing
systems
Exhaust
5. Copyright © Institut Lean France 2013
Go and see
Objectives :
• go and see for yourself
• understand user needs
• analyze incidents
• control standard execution
3 & 4 October, 2013
Paris, France
6. Copyright © Institut Lean France 2013
Findings in 2006
Need to Improve the
local support &
proximity with users
3 & 4 October, 2013
Paris, France
IT Budgets limited as COMEX
unsure of IT delivery
a real project management
capability was needed
Need to support Faurecia growth
and develop worldwide operations
7. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
The challenge was :
we had to move from a technical,
« push mode » IT:
« I can’t help if
users do not use
correctly the
system »
to a customer / process
focus, « pull mode » IT:
« Let’s try and
understand their
needs »
8. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Refocus on business value
Business
targets
. Processes
. Standards
Project
Management
Technicals
. IT Applications
. IT Infrastructures
Change
. Trainings
. Realign to standards
10. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Explore
TOYOTA WAY
KAIZEN
STANDARDS
JIDOKA
JUST IN TIME
CUSTOMER
SATISFACTION
11. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Customer satisfaction
Reliability of IT services
Jidoka, kaizen, standards
12. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Switch issue
• production line stopped in the plant 1h30
• an IT switch had to be rebooted
1h30 outage
Switch issue
Other cause
?
Time to detect
No monitoring
on switch
?
No alert
from monitoring
13. Copyright © Institut Lean France 2013
Switch issue
3 & 4 October, 2013
Paris, France
• 1h + was spent finding a forklift and a
certified operator
• to reach the switch, located high above
production lines
1h30 outage
Switch issue
Not an IT standard
Enforced by contractor
when building plant
Other cause
Time to detect
No monitoring
on switch
Time to reboot
No alert
from monitoring
Too high
Prevent damage
when handling products
Forklift & operator
unavailable
14. Copyright © Institut Lean France 2013
Switch issue
3 & 4 October, 2013
Paris, France
• What would have happened before :
- Nothing (service restored)
- At best change the switch in the plant
- Or challenge the monitoring solution
• What we try to do now :
- Confirm why it happened : new plant building process
- Confirm why we did not see it coming : IT FMEA done too
late and not complete
- Correct to prevent re-occurrence in that plant
- Address risk in all plants : IT standards, Building standards
17. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Our Jidoka process
•
•
•
•
•
•
•
Create standards
Define conditions for IT alerts (gap vs standard)
Restore service asap (protect the customer)
Analyze potential factors -> reduce scope
Dig down to root causes (5 whys)
Change local standard (or create it)
Transversalize
18. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
And
measure
user
satisfaction
Problems to
investigate
19. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Customer satisfaction
Work on ergonomy
20. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Ergonomy
5 windows
8 Clicks
Click on Apply to save the modification
Click in the fields to change:
the quantity value
or F/N value
or Ref Des value
Source : Magellan user documentation
Before :
5 windows, 8 clicks
After :
drag and drop
21. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Ergonomy
Use cases defined, regular
reviews with users
22. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Create value
Standard solutions
Improve data flows
23. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Understand big picture
CUSTOMER
DEVELOPMENT
OPERATIONS
Plant
R&D
CENTER
Plant
CONTRACT
Design
Simulations
Capex, tooling
Change management
START-UP
Operational excellence
Plant management
Cost, PPM, MPM
24. Copyright © Institut Lean France 2013
Complexity increases
MORE AND MORE
BEFORE
Supplier 1
3 & 4 October, 2013
Paris, France
Plant
Supplier 1
Supplier 2
Crossdock
Supplier 2
Supplier 3
Plant 1
Consolidation
center
Supplier 3
Plant 2
Self billing
invoicing
Supplier 1
Supplier 1
Supplier 2
Supplier 3
Just in
Time
plant
Customer
Product
invoicing
Assembly
invoicing
Supplier 2
Supplier 3
Just in
Time plant
Customer
25. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
IT needs for a lean company
• Standards (re-use), yet offering flexibility and
reliability
• Leveling tools
• Measurement, transparency on key process
steps (make problems visible)
• Alert systems (Jidoka)
26. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Develop standard applications
– Plant functions (production, logistics, finance,
purchasing)
– JIT (Just In Time) systems
– Traceability systems
– Supply leveling systems
– Workflow tools
– Data mining tools …
27. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Our first breakthrough
From unleveled – pushed flow
To leveled – pulled flow
=> Stock decrease
Manifest
Order
DN
Manifest
Invoice
DN n°
Invoice
Manifest n°
28. Copyright © Institut Lean France 2013
Support stock reduction
Starts with data accuracy
JIT calls
Production
& scrap
declaration
Production
Backflushing
out
in
Scheduling
T arget = 100% Good Deliveries
% RFT
Target
Linéaire (% RFT)
NRFT - Receiving Progress
100,00%
80,00%
60,00%
40,00%
20,00%
2/2
01
3
2/2
01
3
2/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
1/2
01
3
RM & BOP
inventory
MRP
Quality
Inspection
/ product
returns
05
/0
03
/0
01
/0
30
/0
28
/0
26
/0
24
/0
22
/0
20
/0
18
/0
16
/0
1/2
01
3
1/2
01
3
1/2
01
3
14
/0
12
/0
10
/0
1/2
01
3
0,00%
1/2
01
3
Cycle
counting
Receiving
120,00%
08
/0
Part
creation
06
/0
ECM
process
3 & 4 October, 2013
Paris, France
28
30. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Help plants re-align
to Group Standards
Generic change
toolkit
31. Copyright © Institut Lean France 2013
See together
3 & 4 October, 2013
Paris, France
Logistics
Accounting
33. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Toyota Way
Source :
TOYOTA MOTOR CORPORATION GLOBAL WEBSITE (2001)
34. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Growth
supported by
new IT Centers,
no outsourcing
Czech Rep
Portugal
Mexico
Tunisia
China
India
34
35. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Develop autonomous teams
Customer
expectations ?
Make performance
visible
Ensure teams are
autonomous on continuous
improvement
Develop capacity to
solve complex problems
36. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Where are we today ?
Open questions
37. Copyright © Institut Lean France 2013
3 & 4 October, 2013
Paris, France
Open points – next steps
• Are we solving the right problems?
• Are we driving sufficient business value ?
• How can we better support product development ?