Towards achieving a linear output creating a manufacturing framework

Abstract

Need of the hour: Today, at Siemens we are in the midst of a highly competitive post liberalization environment. In order to achieve the substantial and sustained competitive edge we need the quantum leaps in the productivity. Siemens has realized merely setting the initial pace is not enough, the sustenance is required, The top movement at Siemens is all set for that. We are marching fast to the linearity of supply to our customers. This vision can be achieved only through the team working and the goal orientation. This project is an effort to integrate the top movement to the manufacturing in the Metal Parts of Switchgear Division. Here, we are all determined to accelerate this pace of change. The goal: This objective of the project is to synergise the manufacturing activities to the top movement. The goal is to achieve the Linear supply of the Metal component to the Assembly lines. The Approach: This is done through a series of interviews with a cross section of people, by taking the snapshot views of the manufacturing activities in the Metal parts and adding an experience to i t A framework using the Ishikawadiagram and the Gamba-Kaizan techniques is developed. This was discussed and confirmed with the Siemens- management. Finally, it was tested on the Key components in the Metal Parts, the Contacts and the Kombishraube. The results obtained confirmed the validity of the framework. The Quick results:The supply of the mass production variety of the Kombishraube and the all the Contacts was brought to almost near linear. This in monitory terms means reduction of WiP by 10 points and savings of Rs. 1'0 Mil.@ 22% cost of capital. The improvements suggested called for an additional investment of Rs. 80 Mil. and I am happy to say it was gladly sanctioned by the Siemens management, the investment is being done at an attractive rate of returns of 30 % . Besides this there are Lot of non-measurable benefits like ^reductions in material movement , increasing the process accountability and thus the delivery reliability aada considerable relief on the bottleneck machines could be generated. The satisfaction to this effect was expressed in person by the people working there.,