EOQ MNB Hat Szigma és Lean Szakbizottsági ülése
Üdvözlet a Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. nevében
Budapest, 2014 szeptember 23.
Száraz Kálmán Termék minőség mérnökség vezető Knorr-Bremse Group
Tartalom: Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. bemutatása KPS – azaz Knorr Production System – és LEAN kompetenciák TPM és DNC Zero deffect filozófia 5dF és Fabrik des Jahres 2013 Andon rendszer A JIDOKA újra-értelmezése Auditok, Tanúsítványok …. Kérdések és válaszok Knorr-Bremse Group
Answers for a World of Mobility
Every day, more than 1 billion people put their trust in systems from Knorr-Bremse
Knorr-Bremse Group
The Knorr-Bremse Group │3
History of KBU History and Milestones of the Production Plant (old factory)
Purchase and Opening Foundation Ceremony Dec June 1995 1996
Nov 1996
Start of Production
Knorr-Bremse Group
Halle XU
Dispatching Station Dec Jan 1999 2000 new Warehouse
Dec 2002 new Paintshop
July 2004
Freight car shop
Aug. 2005
May 2007
DV-BUD
│4
History of KBU History and Milestones of Production Plant (new factory)
Construction of the Building starts Feb 2009
Nov 2008 Decision to build the new factory
Knorr-Bremse Group
Building completed, STC start Dec20 09 DV-BUD start at the new factory
Mar 2010
Jul 2010 New factory opening after transfer
│5
History of KBU New factory KNORR- BREMSE HUNGARY (KBU)
Facts & Figures
Size: -
Plot size approx. 90.000 m² Factory approx. 26.000 m² Offices/Social areas approx. 6.600 m² Further expansion area approx. 11.000 m²
Employees: - Cca. 1150 employees
Turnrate: 15 will be achieved in 2012 vs. 2014 Knorr-Bremse Group
│6
Main figures Development of Turnover* and Headcount
Headcount
Turnover
* internal KB-Group Turnover (mEUR) Knorr-Bremse Group
│7
Main KPI’s
Turnover share by product groups (sales data from 2013)
CoC Bogie Equipment (BE)
CoC Brake Control (BC)
(80% Turnover)
(10% Turnover)
CoC Air Supply (AS) Repair, service, etc. (2% Turnover)
Knorr-Bremse Group
(8% Turnover)
Main figures Headcount
KBU total headcount - actual
Knorr-Bremse Group
│9
KBU Products and Engineering Products CoC BE for Loco’s
Tread Brake Units
Compact Caliper for Axle mounted Disc RZS
BR185
Knorr-Bremse Group
│10
KBU Products and Engineering Products CoC BE for High Speed Trains Compact Caliper Units WZK
Conventional Caliper
New Pendolino Knorr-Bremse Group
│11
KBU Products and Engineering Products of CoC BE for Metros
Tread Brake Units
Metro Shanghai Knorr-Bremse Group
│12
KBU Products and Engineering Products CoC BE for Freight Cars BG-Cylinder
Slack-adjuster
Knorr-Bremse Group
│13
KBU Products and Engineering
Main Products Segment BC
Components for Freight Cars
Weighing valve LH angle cock
Freight/Passenger change over device Knorr-Bremse Group
Brake hose coupling │14
KBU Products and Engineering Main Products Segment BC Components for Passenger Cars
Emergency box
Valves
Panel equipment
Brake couplings
Change over device
LH angle cock Indicator Knorr-Bremse Group
│15
KBU Products and Engineering CoC AS
Air Dryer • tanks of drying chambers • bracket, houses, piston valve • covers, magnetic valve
Knorr-Bremse Group
Only components for Compressors • crankcases • cylinders, cylinder heads • piston rods, flanges • air inlets
│16
KBU Products and Engineering Selection of References our Products ICN
Bombardier
Switzerland
Flirt MÁV
Stadler
Hungary
Metro Toronto
ROTEM
Canada
Shinkansen
JR-East
Japan
Pendolino
Alstom
Italy, Finland
KZ4A - Pass. Loco KZ8A – Freight. Loco
Alstom
ICE
Siemens
Germany
Metro Caracas
Alstom
Venezuela
Desiro
Siemens
UK, Germany
Kazahstan
│17 Knorr-Bremse Group
KBU Products and Engineering Research & Development – Engineering CoC BE and CoC BC
Engineering CoC Bogie Equipment
Engineering CoC Brake Contol (Pneumatics)
Technical Analysis Finite Element Method
Brake application to railway
Design and development
Finite element modeling of
bogies Design and development of brake caliper units and tread brake units Warranty engineering and design to cost Release tests and serial endurance tests
pneumatical components and brake panels Modularization of valve systems Know how transfer integrated brake control systems Release tests and serial endurance tests
brake units and components Strength calculations of models on the basis of ANSYS or HYPERWORKS platform Stress assessment Preparing strain gauge test of brake units
Knorr-Bremse Group
│18
KBU Products and Engineering Brake Control Panels Tailor-made piped Brake Control Panels with Standard - Components • high Project-Flexibility
• short Development-Time • proven Design • System-Test prior Installation • fast Installation • low Maintenance Costs
Knorr-Bremse Group
│19
KBU Products and Engineering Research & Development – Electronics
Software Development (safety relevant and others)
System Qualification and Diagnosis
Hardware Development
Development and verification
Design, development, test and
Development and
of safety relevant sofware up to SIL3 (Safety Integrity Level 3) Development of brake control functions, such as Wheel Slide Protection Driver assistance systems
release of complete brake systems Vehicle dynamic simulations and system tests up-to 550km/h Vehicle tests with remote data logging Complete diagnostic of onboard systems
qualification of embedded electronic hardware Obsolescence management Simulation of failure probability, and timing issues
Knorr-Bremse Group
│20
Manufacturing competencies
Knorr Production System (KPS) = Continously Improved Processes Productivity / Efficiency / Flexibility
Quality
• Machining processes (internal and external) • Surface treatment technology • Assembly methods • Logistic methods / SCE– 5dF Approach • Product quality Zero Defect approach
Knorr-Bremse Group
│21
Production competencies Machining competency
Applied KPS methods • TPM • Andon, status visualization
• Flexibility matrix • 5S • OEE • SMED • Pull with
CNC Centres for Milling & Drilling
CNC-Centres Turning
synchronization
Knorr-Bremse Group
│22
Quality Control for machined and sourced parts Equipments of Q-Department
FAI inspection by QC Optical scanner
Laser scanner
First-off Measuring by QC
Spectroscope several Hardness and Shore Hardness Tester Spring Force Tester Profile-Projector Contour graph Coating Thickness Tester Roughness Tester Magnetic Crack Detector Salt Spray Chamber Conditioning Cabinet (-70°C – +170°C ) Laser scanner White stripe (optical) scanner
Self Inspection by Operators 5 x Wenzel LH87 X=800, Y=1500, Z=700 accuracy : U3 = 2,5µ+L/450
• several 2D measuring machines • more than 15000 gauges
1 x Wenzel LH87 fix head X=800, Y=1500, Z=700 accuracy : U3 = 1,7µ+L/350 Knorr-Bremse Group
│23
Production competencies Surface Treatment (STC) competency
Applied KPS methods • Pull with synchronization • Continous flow • Waste elimination • 5S • Visualization
• Shop floor KPI
Knorr-Bremse Group
│24
Production competencies Assembling competency
Applied KPS methods • Pull-Principle • One-Piece-Flow • PFMEA • Poka-Yoke
• CAA • Flexibility matrix • 5S • KANBAN • Visualisation • Standard work • TPM Knorr-Bremse Group
│25
Competence of Machining - Total Productive Maintenance (TPM)
All CNC machines are in DNC • online Info of machine failure via SMS and email • download of CNC programs • m/c status visualization • planning of work orders • analysis of utilzation working planned TPM no work
breakdown wait for new series set up quality control 1st-off Knorr-Bremse Group
│26
Strategy and advanced methods Zero Defect approach
Source Inspection using Poka Yoke BEST
Operation
Feedback Loop
Mistake Defect Defect Found at next process stage Defect found at end of line
Judgement Inspection
Defect found within factory
Judgement Inspection
Defect found at customer
Knorr-Bremse Group
Successive Inspection: Checked and controlled by the next person, operation
WORST
│27
Logistic challange / 5-day-Factory
The 8 principles
The 5-Day-Factory Hungary (5 days throughput time)
Orders Machining
Orders Assembly
1
Transparent information processes to improve communication
2
Integration of design into the plant for short and direct feedback
3
InSupply ensures a material availability close to 100%
4
Cells for complete parts machining incorporate all relevant technologies
5
Integration of the Shared Technology Centre (STC)
6
One-piece-flow assemblies applying standard work procedures
7
Heijunka planning to level the production by quantity and sequence
8
Value stream based layout for short and transparent material flows
7 2 days
3
Source
4 Machi- 5
InSupply External Machining
ning
1.5 days
1.5 days
6 Assembly Shared and Technology Test Centre
Deliver
1 2 8 │28 Knorr-Bremse Group
│28
The business challenge and our solution
Awards for the 5dF approach and implementation – BEST VALUE STREAM proc Fabrik des Jahres
2013
elog@istics 2013
Knorr-Bremse Group
│29
Robust Processes KBU
Automatic Stop / Andon system
ANDON case – Start of issue Shift leader, Process controller decides within 5 minutes if they need escalation or not.
ANDON 1. LEVEL
+15 minutes
ANDON 2. LEVEL
+10 minutes
ANDON 3. LEVEL
•Engineers
•Team leaders
(SQA, design, assy proc.…)
Department leader
(SQA design, assy proc …)
Quality Manager, Design Leader STC Leader Technology leader
•STC shift leader
Knorr-Bremse Group
•STC leader deputy •Assy process team leader
│30
JIDOKA – Hogyan is értelmezzük ?! - „AUTONOM(ous oper)ATION” - 1 1. A Termelés feladata 1.) Konstrukciós követelmények teljesítése 2.) Csökkenteni (Szabályozni) a változékonyságot
2. A termelés kulcs pontjai = “JIDOKA” „AUTONOM(ous oper)ATION” Folyamat gazda garantálja a termékminőséget a saját folyamatában A folyamat gazda fel van vértezve a jó-nem megfelelő közötti döntés jogkörével Csak minőségileg 100%-ban igazolt termék küldhető tovább a következő folyamatlépésre Jidoka
Jidoka Machining
Source InSupply External Machining
Jidoka
Shared Technology Centre
Jidoka
Assembly and Test
Deliver
Jidoka
Knorr-Bremse Group
│31
JIDOKA – Hogyan is értelmezzük ?! - „AUTONOM(ous oper)ATION” - 2
3. Hogyan vezessük be a “JIDOKA”-t minden termék-életciklus fázisra “JIDOKA” a
Jó műszaki Tervezési = rajz és fázisban követelmény
“JIDOKA” a
Folyamat fejlesztési fázisban
=
“JIDOKA” a
Termelési fázisban
Jó = folyamat ellenőrzés
Knorr-Bremse Group
Jó folyamat kialakítás
Jidoka
1.) Konstrukció, ami tiltja a rossz összeszerelést – Design to Assy 2.) Könnyen végrehajtható, Könnyen érthető a Jó és Nem-megfelelő termék állapot (OK / NG) 3.) Kis termelés irányítási leterhelés (pl. standard alkatrészek egységesítése) 1.) Magas folyamatképesség 2.) Könnyen végrehajtható, Könnyen érthető a jó és Nem-megfelelő termék állapot (OK / NG) 3.) Megállás nem-megfelelő termék esetén 4.) Tiszta jelölése a karbantartott készülék és eszköz állapotnak 1.) Könnyen végrehajtható, Könnyen érthető a Jó és Nem-megfelelő termék állapot (OK / NG) 2.) Standard * munkafolyamat, ami garantálja a jó minőséget követéskor 3.) Terv és erőforrások a megfelelő karbantartáshoz
Jidoka
Jidoka
Jidoka
│32
JIDOKA – Hogyan is értelmezzük ?! - „AUTONOM(ous oper)ATION” - 3 4. Standardizálás (= Normálizált állapot):
~Csökkentett változékonyság, Problémákra összpontosított figyelem~
1.) Könnyen végrehajtható Ha az operátor nem képes követni a Standard munkafolyamatot → 2.) Könnyen érthető Nem szabályozott állapot 3.) Könnyen követhető 4.) Rendszeresen ellenőrzött és frissített (← legfontosabb) Munkautasítás - részlet
Knorr-Bremse Group
Munkautasítás lebontás (JIB) - részlet
│33
JIDOKA – Hogyan is értelmezzük ?! - „AUTONOM(ous oper)ATION” - 4
5. Hogyan oktassuk ki a Standard munkafolyamatot? Munkautasítás lebontás (JIB) - részlet
Ki végzi
1. darab
2. darab
3. darab
Oktató
→
→
→
4. darab
5. darab
6. darab
←
←
←
Betanuló Knorr-Bremse Group
│34
Audits per year
Nr of Audits 16
14
ISO14001 ISO14001
ISO9001 ISO9001
ISO14001 ISO14001
ISO14001 ISO14001
ISO14001
ISO9001 ISO9001
ISO9001 ISO9001
ISO9001
TSI TSI
TSI
12 12 10 10 8 8 6 6 4 4 2 2 0 0 Knorr-Bremse Group
2001 2001
2004 2004
2009 2009
Future? 2014
Strategy and advanced methods KBU - Winner of the National Quality Award 2005
Knorr-Bremse Group
│36
Selection of successfully passed Audits, Certificates
1997 Jan. DB-Audit, Q1-Level 1998 Dec. ISO 9001 Audit 1999 Dec. ISO 14001 Environment Audit 2000 Jan. DIN 6700 Welding Audit 2000 Mar. Customer Audits 2003 Nov. REX implementation, combined audit 2005 Oct. Hungarian Quality Award 2006 Jun. TSI audit for freight car parts 2009 Febr. IRIS audit – OHSAS18001:2007
2012 Dec. Bonding DIN6701-2 2013 Jun. IT Security ISO 20000-1 2013 Dec. Fabric des Jahres Best Values Stream Knorr-Bremse Group
│37
Kérdések és Válaszok ?!?!
Knorr-Bremse Group
Köszönöm a figyelmüket!
Knorr-Bremse Vasúti Jármű Rendszerek Hungária Kft. Helsinki út 105 Budapest, Magyarország H-1238 Száraz Kálmán Termék Minőség Mérnökség Vezető
Knorr-Bremse Group
www.knorr-bremse.com
Phone: +36 1 2894 216 Fax: +36 1 2894 261 Mobile: +36 70 414 96 13 E-mail: kalman.szaraz @knorr-bremse.com
