Introduction Introduction Anders Davas Work Experience - - PDF document

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The Aerospace & Defense Forum OC Chapter September 6, 2012 This is a photographic template your photograph should fit precisely within this rectangle. Operational Excellence - (Re)Structure for growth and stakeholder value Anders


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The Aerospace & Defense Forum – OC Chapter September 6, 2012 1

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Operational Excellence - (Re)Structure for growth and stakeholder value

Anders Davas Eaton Aerospace Aerospace & Defence Forum - Orange County Chapter September 6, 2012

Introduction Introduction

Anders Davas

  • Work Experience
  • Division Manager

Eaton Aerospace

  • VP & GM

Telair International (A Teleflex Company)

  • Strategic Development

Teleflex

  • Operations Director

Ensas

  • Education
  • The Wharton School

2 2

  • University of Cambridge
  • Chalmers – University of technology
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The Aerospace & Defense Forum – OC Chapter September 6, 2012 2

Introduction Introduction

Eaton Aerospace - Fuel & Inerting Systems

Pedigree

  • First electric boost-pump manufacturer
  • First composite-wing integrated system
  • Complete ground-to-engine capability

Pedigree

  • First electric boost-pump manufacturer
  • First composite-wing integrated system
  • Complete ground-to-engine capability

Refueling Nozzle Engine Feed Flexible Coupling Technologically Advanced Thermally Efficient Fuel Pump Pressure

Key Platforms

  • Boeing 787
  • Airbus A380
  • Sikorsky CH-53K
  • KC-46A

Key Platforms

  • Boeing 787
  • Airbus A380
  • Sikorsky CH-53K
  • KC-46A

Complete ground to engine capability

  • Pumps for all power sources

Complete ground to engine capability

  • Pumps for all power sources
  • Northrop X-47
  • Eurofighter
  • Learjet 85
  • KC-390

Engine Feed Tube Transfer & Scavenge Jet Pumps Pedestal Mounted Ball Valve Pressure Transducer

3 3

Future Platform Innovations

  • Composite conveyance & equipment for

low-cost, light-weight composite wings

  • Integrating in-tank sensing with inerting

control for reduced bleed consumption Future Platform Innovations

  • Composite conveyance & equipment for

low-cost, light-weight composite wings

  • Integrating in-tank sensing with inerting

control for reduced bleed consumption

Engine Feed Pump and Canister Motor Operated Shut-off Valves Motor Control Unit Air Separation Module Digital Fuel Gauging

Introduction Introduction

Agenda

  • Introduction

4 F M d l

  • 4-Focus Model
  • Strategy
  • Processes
  • People
  • Systems

4 4

  • Pilot Implementation
  • Q & A
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The Aerospace & Defense Forum – OC Chapter September 6, 2012 3

Introduction Introduction

Operational Excellence Model – Proven results

2009 40% 2010 43%+ 2011

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EBITDA Margins

Introduction Introduction

Turn Operational Excellence into a competitive advantage Value Company move to the left i b

  • Increasing Labour Cost
  • Decreasing Labour force

Frontier move to right

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Cost

  • Competition moving to

emerging markets

  • Availability of new labour
  • Competition is becoming

better or cheaper Improve performance/value Delivery, Quality, & Cost

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 4

Introduction Introduction

4-focus approach to operational excellence

  • Strategic Planning
  • Strategic Deployment
  • Goal Setting

1. Strategy 2. Processes 4. Systems

  • Value Adding
  • Standardized
  • Continuous Improvements
  • Automate
  • ERP Efficiency
  • Poke‐Yoke
  • Visual Mgmt

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3. People

  • Accountability & Commitment
  • Engagement & Development
  • Competence & Confidence

This is a photographic template – your photograph should fit precisely within this rectangle.

Strategy

Strategy Processes People Systems

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 5

Strategy Strategy

Key dimensions of a strategic plan

Business Unit & Group Overview Market Analysis SWOT Analysis (situation analysis)

Strategic Plan ‐ Growth

p Technology Road Map Product Developments Competitive Analysis Investment Opportunities

V l P iti V l P iti

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Product Strategy Product Strategy

Value Proposition Value Proposition

  • Mfg. Strategy
  • Mfg. Strategy

Internal External

Strategy Strategy

Value analysis to identify core manufacturing activities

Core Non-Core

Product/Process

High Utilization

  • n

Maintain/ Optimize Outsource BCC

uct/Process

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Low Utilizatio

Right-size / Consolidation

Outsource Experts

Produ

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Strategy Strategy

Maximize performance through best manufacturing practice

V i ti R d ti & 5S, Visual Management & Kan-Ban Parts withdrawal Super Market Line feed Milk-Run

Flow cells Material Pull

Smoothed production

Flexible & leveled production

Variation Reduction & Six Sigma

Six Sigma processes Visual Factory

Balanced & Standard Operations Flexible Cells & Error Proofing Standard Work instructions

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VSM, Product Grouping & Capacity Planning , g Tiered Meetings

Move beyond 5S+ to unlock potential in organization.

Paced ops Visual Factory

Strategy Strategy

Deployment – Create alignment, accountability and commitment.

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Strategic deployment matrix and scorecard ‐ Organizes thinking and links action to strategy ‐ Aligns functions for goal setting ‐ Identifies/Establishes break‐through actions ‐ Provides tools for continuous improvement ‐ Communicates goals and performance

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 7

Strategy Strategy

Set stretch metrics and identify breakthrough initiatives HOW FAR

All items are listed in priority order i f

HOW HOW MUCH WHO

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FAR

starting from the center

WHAT

Strategy Strategy

The whole picture of your company on one sheet of paper

Use dots to show l ti hi f Use dots to show relationship of Targets and Resources to the Improvement Priority

HOW FAR HOW HOW MUCH

relationship of Improvement Priorities to Annual Objectives NOTE: Only Solid dots on a resource deploy to the next level Use dots to show relationship of Annual 14 14

FAR WHAT MUCH

relationship of Annual

  • bjectives to 3 year

strategic plan

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 8

Strategy Strategy

Example of SD-Matrix

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Strategy Strategy

Improvement priorities cascaded to the point of impact

Top Level – Company/Group Action Plan Second Level – Plant/Business

The level where root causes are addressed! Action Plans can be initiated out of any matrix level.

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Third Level Sub Plant/Dept

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Strategy Strategy

Each target is copied to the SD score card

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Strategy Strategy

Action plans drive the rate of improvement

ACTION PLAN ACTION PLAN

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Processes

Strategy Processes People Systems

Process Process

Lean Management Philosophy

Standard Accountability

Process Process Focus Focus

  • PDCA

PDCA -

  • Leader

Visual Controls Accountability Processes

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Standard Work

A Foundation for Operations Excellence

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Process Process

Good Leaders Execute & Improve Planning Planning Planning Planning

  • Strategic Planning
  • Strategic Deployment

P fit Pl i

Plan Do Check Act

A‐Work Work A‐Work Work

Business Operating System

  • Balanced Scorecard
  • Standard Work
  • Visual Management
  • GEMBA
  • Accountability
  • HPWT

B‐Work Work B‐Work Work

Business Operating System

  • VSM
  • GEMBA
  • Root Cause Analysis
  • Process – FMEA
  • Lean Six Sigma LSSS
  • HPWT
  • Lean Councils
  • Profit Planning

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A‐work – Value Creation Process – Delivery & Quality + B‐work – Improvement Process – Faster, Better & Cheaper = Focused team with a continuous improvement culture

Lean Councils

Process Process

Tiered meeting accountability and execution process – A-Work Tier 3 Agenda / Focus Agenda / Focus

  • Mfg Manager
  • Value Stream Leader

Attendees Attendees

Escalation

  • Daily performance data (yesterdays)

‐ Safety

Ti 1 Tier 2 Tier 3

  • Cell Lead
  • Team members
  • Support Mgr
  • Values Stream Leader
  • Cell leaders
  • Support group

Escalation

  • Labour Plan
  • Daily rotation

y ‐ Quality ‐ Delivery ‐ Cost

  • Overdue items and actions
  • Labour Plan
  • Daily rotation
  • Plant Issues
  • Improvement actions

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Tier 1

  • Team members
  • Daily rotation
  • Cell issues/solutions (Forward looking))

Develop efficient Tier Meetings:

  • Short and crisp
  • Stand-Up
  • Visual
  • Close to workplace
  • Structured and standardized agenda
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Process Process

Example - Tiered Meetings in action….

A t bilit B d A W k M t i B d Accountability Board A‐Work Metrics Board

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Process Process

Standard leaders work to ensure leaders react to signals

Standard and aligned schedule

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Process confirmation

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On Time Delivery %

Owner : Anders Davas PERFORMANCE TREND

80% 90% 100% Actual Plan 3,000 3,500 4,000 YTD Month

  • 1. Actual vs. Plan

Assess the impact

Process Process

Data driven improvement process – Balanced Scorecards – B - work

2009 2010 2011 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Actual 77% 79% 73% 69% 72% 69% 71% 78% 78% 80% 0% 0% 0% 0% 0% Plan 86% 86% 85% 74% 76% 77% 78% 79% 80% 81% 82% 83% 84% 86% 87%

Key Metric Data

0% 10% 20% 30% 40% 50% 60% 70% ‐ 500 1,000 1,500 2,000 2,500 Jan Feb Mar Continued performance issues in TF & SM. MCOE on site, review of porogress underway. 3 Tier meeting refreshed in TF. Euclid recovery in Feb >90% following Maini resource Improved OTD at all plants except Euclid where FMS machine failure, furnace relining and continuing BCC supplier issues have held performance flat at 85%. Major impact from Euclid due to FAA issue

Commentary

  • 2. Pareto analysis

Prioritize the impact

  • 3. Commentary

1 2

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Mar Apr May Jun Jul Aug Sep Oct Nov Dec Ref Owner Open Due 1 PM Apr-12 May-12 2 RD/WD Apr-12 on-going 3 ED May-12 Aug-12 4 LB/DB Jul-12 on-going 5 Ref Owner Open Due 1 M Mula Feb-12 Feb-12 2 3 4 5 Reflect Airbus progress Major impact from Euclid due to FAA issue. Continued revovery in SM, TF Airbus driving improvements but hampered by strangers/legacy performance MCOE CI process in Sdouth Molton , bi-w eekly review s

Action Items

Recovery in South Molton, slow imporvement at TF, EU flat driven by shaft cell thourgh put issues Promise dates availability Actions agreed with DVP Operations Status (provide details of progress or state "Closed") EU improvement hampered by continuing shaft yield issues Divison Actions Status (provide details of progress or state "Closed") Results/Impact EU - Foucs on w ork order release in OE, saft recovery actions Thorugh-put focus, Six sigma expert in place to drive yield issues OE OTD focus Results/Impact Line by line Arrears analysis Analyses in place, line item avtion plans and due dates in the systems TF - MCOE CI porcess read across to all value streams in TF Bi-w eekly review s in place. MCOE team allocated Customer Green team - taskforce being rolled out to accelerate improvement Review manufacturing capacity constraints w ith Plants Trade and IC improvement

y Identify Root Cause

  • 4. Improvement action plan

Drive Short term containment Implement Long term prevention

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People

Strategy Processes People Systems

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 14

People People

Transition away from a traditional manufacturing organization

Plant Manager

Manufacturing Quality Engineering Supply Chain Manufacturing Engineering Human Resources Continuous Improvements

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Department Manager 1 Department Manager 2 Department Manager 3

People People

To a value stream centric organization with high performing teams

Plant Manager

Quality M.E C.I Quality M.E C.I Quality M.E C.I

Value Stream Manager Value Stream Manager Value Stream Manager

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Supply Chain Planning EHS Supply Chain Planning EHS Supply Chain Planning EHS

Cross functional teams Located close to workspace

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 15

People People

Redefine the Role of the Front Line Leader Supervisor Supervisor Front Line Leader Front Line Leader p Selected based on technical capability / process knowledge

  • Directive (“Do as I say”)
  • An Expediter
  • Disciplinarian
  • Supportive / Coaching
  • Intrinsically motivated
  • Future vision orientation

Selected based on leadership Competencies

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Disciplinarian

  • Enforcer
  • Top‐down

Future vision orientation

  • Life‐long learner

People People

Attract the right leaders

Leaders need to…

P id th i i d t t

  • Provide the vision and strategy
  • Lead by example – be a positive role model
  • Actively engage and recognize employees
  • Enable success of your employees (resources, barriers)
  • Empower the employees – drive decision making down

th h i ti

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through organization

Empowerment Empowerment

Leadership to create the environment

Values and ethics Values and ethics

A balanced Leadership Team

Engagement Engagement

Leadership to drive and stimulate change

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This is a photographic template – your photograph should fit precisely within this rectangle.

System

Strategy Processes People Systems

System System

Create flow cells and an environment to support flow.

High productivity High productivity assembly cell assembly cell

Kan-Ban driven Super Market Poke-Yoke Line Fed material at Point of Use System

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Pace board A-Work Bar-Coding

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Moving Forward Moving Forward Moving Forward

Pilot Line

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The Aerospace & Defense Forum – OC Chapter September 6, 2012 18

Moving Forward Moving Forward

Systematic approach to achieve excellence

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