精益制造和供应链集成.ppt

andSupplyChainIntegrationPresentedby JerryB KhouryCaliforniaManufacturingTechnologyCenter CMTC LeanManufacturing LAIPlenaryConference Overview HistoricalPerspectiveIndustryConsolidationViewfromOEMsCurrenttrendsDoD R DBudgetsremainflatEmploymentFutureTechnologyTrendsThepoweroftheinternetResourcesSummaryandUltimateGoalQ A HistoricalPerspectiveIndustryConsolidations MergersContinuesataLessorPace Mid80 stomid90 s37became4Mid90 stopresentnoticeableincreaseinM Aactivitywithinsupplychains AstheConsolidationContinuesPrimes OEMsHavenewChallenges Notallsupplierspossessresourcesandcapabilitiestoundertakemajorimprovements sixsigma leanmanufacturing continuousimprovement Notallsuppliershaveabilitytoattract retainhighcaliberpeoplewhounderstandprocesscontrol CpK 6Sigma Demographics theagingworkforcecreates KnowledgeManagement challengesEffectiveCommunicationlinksbetweensub tiersuppliersandendusersbecomeincreasinglyimportantEarlyinvolvementinthedesign developmentphases andteaming beyond theshopfloorbecomemorecrucial CurrentTrends Defensebudgetwillgrowatabout4 withammunitionandaircraftleadingtheincreaseR DBudgetswillremainflatforcingmorePrime SuppliercollaborationSupplierconsolidationwillcontinueasaresultofmergersAsprimesshiftto lean practices supplierswillbeaskedtomanufacturemoremajorsub assembliesandlesspieceparts CurrentTrendsContinued OEMswillcontinuetooutsourcemanufacturingJITdeliveriesinsupportofPOUdemandwillbecomemoreprevalentinordertoreduceinventoryandcarryingcostsOEMswillshiftto assemble test andship modelSuppliersandcustomerswillteam beyond theshopfloortodesignanddevelopnextgenerationproductsusingtheInternettocreateVirtualProductDesignandInnovation DoDProcurementGrowingat4 Mil AerospaceR DFundingRemainsFlat LessR Dwillcreatemorecollaborationbetweenprimesandsuppliers AerospaceisImportanttotheUSAccountsforMajorityofExports Billion DataSource CaliforniaEmploymentDevelopmentDepartment EmploymentInSouthernCalifornia ImportancetotheStateofCalifornia ExcludesservicesestimatesbasedonSICcodeinformation coveragecompensation Includesallindustrysegments bothproduct andservice oriented Approximately138 000jobsinprimaryA DSICcodes plusanestimated50 000jobsfor mixedsuppliers thatservemultipleindustriesinadditiontoA D Aerospaceis2ndLargestEmployer 1996 Million SouthernCaliforniaPayrollsByIndustry Entertainment LeanMigrationThroughouttheSupplyChain EconomicsareforcingOEMs Primes toadopted lean asanenablingtechnologytoreducemanufacturingcostsandeliminatewasteTieronesuppliersarewellontheirwaytoimplementingleanbasedinpartonencouragementfromtheircustomers Sub Tier suppliersstillresistimplementationofleanwithouta BusinessCase andpaybackanalysis ROI TheAerospaceSupplyChainNeedstoAcceleratetheShiftto WorldClass Status PhaseIApprovedSupplierCapacityplanningSchedulingsystemsQualitysystemsComputerizedinformationsystemsInternalassessments PhaseIIPreferredSupplierLeanmanufacturingAdvancedqualitysystemsElectroniccommerceStrategicplanning PhaseIIIStrategicPartnersIntegratedcustomerteamsTotalqualitySub contractorteamsFunctionalprocurementspecifications Bestpractices LeanManufacturingVirtualProductDevelopmentE Enabledtransactions WorldClass TheNewRealities Primes OEMs willcontinueto outsource atanincreasedpaceMoreemphasiswillbeplacedon sub assembly ahigher BOM levelPrimeswillfocuson engineering designexcellence notonmanufacturingPrimeswillusetheInternettoimprovedesign cost schedule qualityandplanningsynergies Agoodstartingpoint Hostedby Willimpactupto37 000suppliers HundredsofAirlines Totalcombinedprocurementoutlayof 71billion 92 99 41 ProjectedBusiness to BusinessE CommerceTransactions Organizationsareincreasinglyturningtotheinternettosourceindirectgoodsandservices thosegoodsandserviceswhicharenotapartofcostofgoodssold Thistypicallyincludessuchitemsasofficesupplies travel temporaryservicesanddesktopcomputers C M T C800 300 CMTC LosAngeles OrangeCounty InlandEmpire GreaterSacramento SanFernandoValley SanGabrielValleySanJoaquinValley Ventura SantaBarbara 4 YearEst Growth CurrentEst 7Tril By2004 GeneralElectric E Commerce JackWelch CEO Thiscompany likeeverycompanyintheworldtoday isinthemidstofthebiggest mosttransformationalrevolutioninthepastcentury broughtonbytheInternet WheredoestheInternetrankinpriority It snumberONE TWO THREEandFOUR OEM s Primeswant WorldClass suppliers SomeTechnologyFacts IBM Bandwith willleapfrogGrewbyafactorof10Xoverthepast15yearsWillgrowbyafactorof150Xoverthenext15yearsIn1995 1TeraFlopcomputerplayedchesscomparablebrainpowerofalizardBy2010 100TeraFlopcomputerwillworkonGenefoldingprojectsBeforetheendofthedecadetherewillbe1to10PetaFlopcomputers12to15PFapproximatehumanbrain AdditionalTechnologyTrends WaveDivisionMultiplexing WDM willbecomecommonplacewithFiberOpticcabletothehouseandofficeWirelessinterconnectionwillbeglobal nowavailableinL A Internetwillbeintegratedintocommonappliances atlowornocosttotheconsumerInternettechnologywillbeintegratedintomachinesandotherhardwareproductsfor7 24monitoringcapabilitiesVirtualteamswillbeformedtodesign virtualproducts on line7 24onaglobalbasis These virtualteams willbe unformed untilthenextproject TheInternetPresentsThreatsandOpportunities OPPORTUNITIESCompetitiveadvantage levelstheplayingfieldAwaytoexpandmarketreachAcceleratestimetomarketandlowerscostsEnhancescustomerrelationsEmpowersemployeesandcreateswhatBillGatescalls KnowledgeWorkers Streamlinesprocesses reducescostAllowsfor7 24globalproductdesignAllowsforrapid productmorphing tomeetchangingcustomerneedsAllowsforglobaltradingpartnersAllowsfor virtualteams tobeformedandunformedbasedonneed ThreatsCreatesInternationalcompetitiononamassivescaleAllowsfor7 24globalproductdesignreducingrelianceondomesticlaborChallengestraditionalthinkingandtraditionalbusinessmodels TangibleBenefitsReductioninTransactionCosts Bankingindustryreducestransactioncostsfrom 1 07to 0 01Travelagentbookingsgofrom 10 00to 2 00Trade procurements transactioncostsgofrom 150 00to 6 00Example Raytheonreducesprocessingcostfrom 100to 3 IndustrialAgeE Commerce ThenextrevolutionwillbeB2G BusinesstoGovernment WebEnabledTradingSite Federal StateandLocalGovernmentsspend 1 6TrillionongoodsandservicesTexaswebsitehasreducedtransactioncostsby83 from 120to 20CaliforniaiscurrentlyevaluatingandtestingE Commercesolutions IntegratingtheSupplyChain Supplierswillneedtobeabletorespondtoelectronic pullsignals withfirsttimequalitytosupportvirtual Kanbans Supplierswillneedtobe E enabledtoreduceadministrativecostswhilereducingcycletimesforspecificationchanges quantitychanges andschedulechangesCustomerswillcontinuetodemandquality price delivery anddesignandintegrationsupport ASSEMBLER22 SUPPLIERS 35 1STTIER22 2NDTIER10 3 4THTIER3 WhyIsThereaConcernWiththeAerospaceandDefenseSupplyChainandSupplyChainManagement RAWMAT L43 ValueStreamCostDistribution RecentUSAFandMITEstimatesIndicate70 80 ofValueisinsupplychain OtherFactorstoConsider AsOEMsuseleantoreduce directlabor and inventory overheadcostsbecomealargerpercentageoftotalcostOneprimeindicatedthat direct manufacturingcostsare20 oftotalcostsThiswillforce lean beyondtheshopfloor LeveragingthepoweroftheInternetcanhelpreduceoverheadcosts CMTCisWorkingonLeanBeyondtheShopFloor Courseworkandtrainingmaterialsarebeingdevelopedthroughacooperativegrant includingaKnowledgeManagementmoduleWorkingwithIBM OtherstoidentifyopportunitiestoleveragetechnologyOneclienthasdemonstratedsignificantsavingsandtimeintheprocurementareaandinthequalityrecordsarea Lean EliminatingtheWastes Typically95 ofTotalLeadTimeisNon ValueAdded RUNTIME OrderProcessing Transport Storage Waiting Rework MachineSetup Inspection MachineBreakdowns etc TotalLeadTime DefinitionofValueAdded ValueAddedAnyactivitythatincreasesthemarketformorfunctionoftheproductorservice Thesearethingsthecustomeriswillingtopayfor Non ValueAddedAnyactivitythatdoesnotaddmarketformorfunctionorisnotnecessary Theseactivitiesshouldbeeliminated simplified reducedorintegrated Thingsthecustomerisnotwillingtopayfor 8WastesofLEAN LeanBuildingBlocksWhataleanfactorylookslike KeystoSuccess PrepareandMotivatePeopleWidespreadorientationtoCI quality trainingandrecruitingworkerswithappropriateskillsCreatecommonunderstandingofneedtochangetoleanEmployeeInvolvementPushdecisionmakingandsystemdevelopmentdowntothe lowestlevels TrainandtrulyempowerpeopleShareinformationandmanageexpectationsIdentify empowerchampions particularlyoperationsmanagersRemoveroadblocks i e people layout systems Makeitbothdirectiveyetempowering KeystoSuccess AtmosphereofExperimentationToleratemistakes havepatience etc Willingnesstotakerisks Safetynets Install enlightened andrealisticperformancemeasures evaluation andrewardsystemsDoawaywithrigidperformancegoalsduringimplementationDomeasureresultsandnotnumberactivities eventsTieimprovements longterm tokeymacrolevelperformancetargets i e inventoryturns quality delivery overallcostreductions Execute pilot projectspriortorollingoutacrossentireenterprise e g modellines kaizenblitzes Afterearlywinsinoperations extendacrossENTIREorganization ImplementationSuccessFactors ImplementationPeopleneedtounderstandtheirnewrolesbeforechangeisimplementedEstablishtimelinesandtargets establishsomeeasytoachieveneartermgoalsCI ContinuousImprovementTrackimpactsassociatedwithchangesmade Communicatethem Monitor enforce andimprovethesystemImprovementLeapsAvoidmentalityofcollapsingoverthefinishline ImplementationSuccessFactors UnyieldingLeadershipStrategicvisionbasedonleanenterpriseaspartofoverallbusinessstrategy ObserveoutsidesuccessesandfailuresAbilitytoquestionEVERYTHING ask why atleast6timesDeepcommitmenttoEXCELLENCE CaseStudiesDemonstrateResults Youdon tunderstand ourbusinessisdifferent LeanSupplierCaseStudiesDemonstrateImpact Client1 65Employees Familyownedbusiness Annualsavingsofover 37 3Kasaresultofstreamliningpaperflow streamliningtheShipping Receivingprocesses andfloorspacereduction Client2 230Employees Corporation Realizedimmediatecostsavingsof 25 8Kduetoa72 reductioninWIPandinventory Annualsavingsof 16 9Kduetofloor spacereduction laborreduction andsetupreduction Client3 368Employees Corporation Realizedsavingsofover 30Kduetoa63 reductioninWIPandinventory Annualsavingsof 19 3Kduetofloorspacereduction laborreduction andpaperflowreduction Client4 186EmployeesCorporation Goalofa50 actual70 reductioninpaperworkdocumentationprocessGoalof50 actual47 reductionindatapackagebuildtimeGoal25 actual20 reductionindatastoragespacebyUsing5SmethodologyDeliveryleadtimereductionover7daysAnnualsavingsof 480K LeanCaseStudiesDemonstrateResults ExpectDoubleDigitImpact 72 reductioninWIPandinventory63 reductioninWIPandinventory70 reductionindocumentationprocess47 reductionindatapackagebuildtime20 reductioninfloorspace BoeingAircraft RocketdyneDivision Decreasedmanufacturingcostsby97 Cutthedevelopmentcycleby50 from2yearsto1Reducedmanufacturingcycletimeby63 from2yearsto9monthsReducednumberofpartsfromhundredsto6Createdaknowledgedepositoryforre useonsubsequentprojects LeanManufacturingisNotNew OneofthemostnoteworthyaccomplishmentsinkeepingthepriceofFordproductslowisthegradualshorteningoftheproductioncycle Thelongeranarticleisintheprocessofmanufactureandthemoreitismovedabout thegreaterisit sultimatecost HenryFord 1926LessonLearned Createdassemblylinesbutdidn tempowerworkerstoachievecontinuousandsustainedimprovements HowCanYouGetHelptoPreparefortheFuture CMTC OurObjective tohelpsmallandmediumsizemanufacturersincreasetheircompetitiveadvantagebyadoptingandimplementingimprovedmethodsofmanagementandmanufacturing Neverunderestimatethe power ofanexternalchangeagent CMTCIntroduction A501c3Private Non Profit CorporationProvideconsultingservicestoCalifornia ssmalltomedium sizedmanufacturersensuringglobalcompetitiveness InformationTechnologyServicesSystemSelectionSystemsImplementatione BusinessLeanEnterprisesServicesLeanAssessmentEnterpriseProcessImprovementInventoryandProductionManagement StrategicBusinessServicesStrategicManagementHumanResourcesStrategiesWorkforceDevelopmentOrganizationandManagementQualityManagementServicesQualitySystemsImplementationProductAssuranceEnvironmentalandSafety Over140ProfessionalsinSevenRegionalCenterswithanaverageofover20yearsprofessionalexperience WePartnerwithGovernmentAgencies TradeAssociations EducationalInstitutions AerospacePrimes GovernmentCaliforniaTrade CommerceAgencyUSAirForceNASA JPLEmploymentTrainingPanelAssociationsAerospaceIndustriesAssociation AIA SocietyofAutomotiveEngineers SAE AmericanInstituteofAeronautics Astronautics AIAA EducationalInstitutionsCommunityCollegeCentersforAppliedCompetitiveTechnologies CACT MIT LAICorporationsAerojet Gencorp BoeingHughes Boeing LockheedMartinNorthropGrummanRaytheonTRW CMTCProvidesTangibleBenefits ReducecostsnotjustsellingpriceReducedeliverytime cycletime set uptimeEliminatewasteSeekcontinuousimprovementImprovequalityImprovecustomerratingsandperceptionsIncreaseoverallcustomersatisfactionImproveemployeeinvolvement moral andcompanycultureHelp transform manufacturers AdditionalResources ManufacturingExtensionPartnership MEP Nationwidenetworkwithover92centerswww mepcenters nist govCMTCProductivityPress LeanMaterials BooksEducationalInstitutionsMITatwww mit eduUniversityofTennesseeSanDiegoStateUniversity NIST MEPCentersareLocatedNearYourSupplyChains Wecanreachanymanufacturerinthecountrywithintwohours MEPCenters DeployingLean aFourPhaseApproach GaintopManagement BuyIn andSupportPerformoverallcompanyassessmenttiedtocompanystrategic operational andmarketingplansDevelopstrategicleandeploymentplanIntegratecustomizedtrainingwithleantoimprovespecificskillsets leveragetrainingresourc