EOQ MNB Hat Szigma és Lean Szakbizottsági ülése · PDF fileEOQ MNB Hat Szigma és Lean Szakbizottsági ülése Üdvözlet a Knorr-Bremse.....

Knorr-Bremse Group

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 The Knorr-Bremse Group

Every day, more than 1 billion people put their trust in systems

from Knorr-Bremse

Answers for a World of Mobility

│3

Knorr-Bremse Group │4

History and Milestones of the Production Plant (old factory)

Dec

1995

Purchase and

Foundation

July

2004

Halle XU

Nov

1996

Opening

Ceremony

June

1996

Start of

Production

Jan

2000

Dispatching

Station

Dec

1999

new

Warehouse

Dec

2002

new

Paintshop

Aug.

2005

DV-BUD

May

2007

Freight car shop

History of KBU


History and Milestones of Production Plant (new factory)

Nov

2008

Decision

to build the

new factory

Construction

of the Building

starts

Feb

2009

DV-BUD

start at the

new factory

Dec20

09

Building

completed,

STC start

Mar

2010

New factory opening

after transfer

Jul

2010

History of KBU


History of KBU

New factory KNORR- BREMSE HUNGARY (KBU)

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

Facts & Figures


Development of Turnover* and Headcount

* internal KB-Group Turnover (mEUR)

Headcount Turnover

Main figures

Knorr-Bremse Group

Turnover share by product groups (sales data from 2013)

CoC Bogie Equipment (BE) (80% Turnover) CoC Brake Control (BC)

(10% Turnover)

CoC Air Supply (AS) (8% Turnover) Repair, service, etc.

(2% Turnover)

Main KPI’s


Headcount

KBU total headcount - actual

Main figures


Products CoC BE for Loco’s

KBU Products and Engineering

Tread Brake Units

Compact Caliper for

Axle mounted Disc -

RZS

BR185


Products CoC BE for High Speed Trains

New Pendolino


Compact Caliper

Units

WZK

Conventional Caliper


Products of CoC BE for Metros

Metro Shanghai


Tread Brake Units


Products CoC BE for Freight Cars


BG-Cylinder

Slack-adjuster


Main Products Segment BC

Freight/Passenger change over device Brake hose coupling

LH angle cock

Weighing valve

Components for Freight Cars



Main Products Segment BC

Components for Passenger Cars

Valves Panel equipment

Brake couplings

Indicator

Change over device

Emergency box

LH angle cock



CoC AS

Air Dryer

• tanks of drying chambers

• bracket, houses, piston valve

• covers, magnetic valve

Only components for Compressors

• crankcases

• cylinders, cylinder heads

• piston rods, flanges

• air inlets


Knorr-Bremse Group

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

Kazahstan

ICE Siemens Germany

Metro Caracas Alstom Venezuela

Desiro Siemens UK, Germany

│17

Selection of References our Products



Engineering CoC Brake Contol (Pneumatics)

Design and development

pneumatical components

and brake panels

Modularization of valve

systems

Know how transfer

integrated brake control

systems

Release tests and serial

endurance tests

Brake application to railway

bogies

Design and development of

brake caliper units and tread

brake units

Warranty engineering and

design to cost

Release tests and serial

endurance tests

Engineering CoC Bogie Equipment

Research & Development – Engineering CoC BE and CoC BC

Finite element modeling of

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

Technical Analysis Finite Element Method



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



Research & Development – Electronics

Hardware Development Software Development (safety relevant and others)

System Qualification and Diagnosis

Development and verification

of safety relevant sofware up

to SIL3 (Safety Integrity

Level 3)

Development of brake

control functions, such as

Wheel Slide Protection

Driver assistance systems

Design, development, test and

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

Development and

qualification of embedded

electronic hardware

Obsolescence management

Simulation of failure

probability, and timing issues



Productivity /

Efficiency /

Flexibility

Quality

• Machining processes

(internal and external)

• Surface treatment

technology

• Assembly methods

• Logistic methods /

SCE– 5dF Approach

• Product quality -

Zero Defect approach

Manufacturing competencies

Knorr Production System (KPS) = Continously Improved Processes


Machining competency

CNC Centres for Milling & Drilling

CNC-Centres Turning

Applied KPS

methods

• TPM

• Andon, status

visualization

• Flexibility

matrix

• 5S

• OEE

• SMED

• Pull with

synchronization

Production competencies


Quality Control for machined and sourced parts

Self Inspection by Operators

First-off Measuring by QC

5 x Wenzel LH87 X=800, Y=1500, Z=700

accuracy : U3 = 2,5µ+L/450

1 x Wenzel LH87 fix head X=800, Y=1500, Z=700

accuracy : U3 = 1,7µ+L/350

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

Equipments of Q-Department

• several 2D measuring machines

• more than 15000 gauges

Optical

scanner

Laser

scanner

FAI inspection by QC


Surface Treatment (STC) competency

Applied KPS

methods

• Pull with

synchronization

• Continous flow

• Waste

elimination

• 5S

• Visualization

• Shop floor KPI



Assembling competency

Applied KPS

methods

• Pull-Principle

• One-Piece-Flow

• PFMEA

• Poka-Yoke

• CAA

• Flexibility matrix

• 5S

• KANBAN

• Visualisation

• Standard work

• TPM



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


Operation BEST

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 WORST

Fe

edb

ack L

oop

Source Inspection using

Poka Yoke

Successive Inspection:

Checked and controlled by

the next person, operation

Zero Defect approach

Strategy and advanced methods

Knorr-Bremse Group

│28

The 5-Day-Factory Hungary (5 days throughput

time)

Deli- ver

External Machining

Machi- ning Shared

Technology Centre

Assembly and Test

Source InSupply

2 days 1.5 days 1.5 days

Orders Machining

Orders Assembly

5 6

7

8 1 2

3 4

Transparent information processes

to improve communication

Integration of design into the plant

for short and direct feedback

InSupply ensures a material

availability close to 100%

Cells for complete parts machining

incorporate all relevant technologies

Integration of the Shared Technology

Centre (STC)

One-piece-flow assemblies applying

standard work procedures

Heijunka planning to level the

production by quantity and sequence

Value stream based layout for

short and transparent material flows

The 8 principles

8

1

2

5

6

3

4

7

│28

Logistic challange / 5-day-Factory


Awards for the 5dF approach and implementation – BEST VALUE STREAM

proc

The business challenge and our solution

elog@istics 2013

Fabrik des Jahres 2013

Knorr-Bremse Group

Robust Processes KBU

│30

Automatic Stop / Andon system

•Engineers (SQA, design, assy proc.…)

•STC shift leader

•Team leaders

(SQA design, assy proc …)

•STC leader deputy

•Assy process team leader

Department leader Quality Manager,

Design Leader

STC Leader

Technology leader

ANDON 1.

LEVEL

ANDON 2.

LEVEL

ANDON 3.

LEVEL

ANDON case – Start of

issue

+15

minutes

+10

minutes

Shift leader, Process controller

decides within 5 minutes if they

need escalation or not.


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 – Hogyan is értelmezzük ?! - „AUTONOM(ous oper)ATION” - 1

Deli- ver

External Machining

Machi- ning Shared

Technology Centre

Assembly and Test

Source InSupply

Jidoka Jidoka Jidoka Jidoka

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)

Jó műszaki

rajz és

követelmény

Tervezési

fázisban

Jó folyamat

kialakítás

Folyamat

fejlesztési

fázisban

=

=

=

Termelési

fázisban

Jó

folyamat

ellenőrzés

1.) Magas folyamatképesség

2.) Könnyen végrehajtható, Könnyen érthető a jó és Nem-megfelelő


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


2.) Standard * munkafolyamat, ami garantálja a jó minőséget követéskor

3.) Terv és erőforrások a megfelelő karbantartáshoz

“JIDOKA” a

“JIDOKA” a

“JIDOKA” a

3. Hogyan vezessük be a “JIDOKA”-t minden termék-életciklus fázisra

Jidoka Jidoka Jidoka Jidoka



4. Standardizálás (= Normálizált állapot): ~Csökkentett változékonyság, Problémákra összpontosított figyelem~

1.) Könnyen végrehajtható

2.) Könnyen érthető

3.) Könnyen követhető

4.) Rendszeresen ellenőrzött és frissített (← legfontosabb)

Ha az operátor nem képes követni a Standard munkafolyamatot →

Nem szabályozott állapot

Munkautasítás - részlet Munkautasítás lebontás (JIB) - részlet



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

0

2

4

6

8

10

12

14

16

2001

Nr of Audits

ISO9001

ISO14001

ISO9001 ISO9001

ISO14001

Audits per year

0

2

4

6

8

10

12

14

16

2001 2004

Nr of Audits

ISO9001

ISO14001

ISO9001

ISO14001

ISO9001

ISO14001

0

2

4

6

8

10

12

14

16

2001 2004 2009

Nr of Audits

ISO9001

ISO14001

ISO9001

ISO14001

TSI

ISO9001

ISO14001

0

2

4

6

8

10

12

14

16

2001 2004 2009 Future?

Nr of Audits

ISO9001

ISO14001

ISO9001

ISO14001

TSI

ISO9001

ISO14001

0

2

4

6

8

10

12

14

16

2001 2004 2009 2014

Nr of Audits

ISO9001

ISO14001

ISO9001

ISO14001

TSI

ISO9001

ISO14001

TSI

ISO9001

ISO14001


KBU - Winner of the National Quality Award 2005

Strategy and advanced methods


Selection of successfully passed Audits, Certificates

2003 Nov. REX implementation, combined audit

1997 Jan. DB-Audit, Q1-Level

2000 Mar. Customer Audits

2005 Oct. Hungarian Quality Award

1998 Dec. ISO 9001 Audit

2000 Jan. DIN 6700 Welding Audit

1999 Dec. ISO 14001 Environment Audit

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

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

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

EOQ MNB Hat Szigma és Lean Szakbizottsági ülése · PDF fileEOQ MNB Hat Szigma és Lean Szakbizottsági ülése Üdvözlet a Knorr-Bremse.....

Documents