Finbarr Dowling Managing Director, Siemens Inverters
Finbarr Dowling
Managing Director, Siemens Inverters
Finbarr DowlingManaging Director
Siemens I DT MC I Congleton
MAS ConferenceJune 16th 2011
Old Trafford
‘Innovate or Die’
Ted Hoff
A long history of innovation
Who we are
1971 Siemens established at Congleton1991 Designated electronics manufacturing factory1996 GZ ASI 1S HQ1999 A&D SD D Design, Manufacture & Technical CS
Total land area:-21,000 m2
Building area (office + production):-12,000 m2
Employees: (510)
Congleton’s manufacturing technologies and products
Sinamics G120 Modular
Micro MasterIntegrated
Sinamics G110
Surface Mount Technology
Through hole Technology
PCB Test Technology Coating Technology Mechanical Technology
Sinamics G120D
Our Competencies
Electronic production of Industrial products in the area of low complexity, high volume Variable Speed Drives & Ancillary equipment on a world class level in regards of excellent product quality, high productivity and highest logistic performance.
Develop robust, competitive product families for the global market with core competence for high IP rated products.
Highly qualified engineering and qualification services for material, processes (incl. Design for Manufacture & Design for Test) and equipment.
Design, programming, manufacturing and documentation of function test equipment for Inverters, Options and HMI.
Professional project management supported by excellent PLM and NPI processes
Third tier Customer Support using the advantage of local production and R&D facilities.
Repair Centre offering NPI dynamic feedback and customer special investigations.
1971-2011 Manufacturing as a % of GDP - UK
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
19
71
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72
19
73
19
74
19
75
19
76
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10
Year
% o
f G
VA
Congleton sales 2002-11
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
2002/03 2003/04 2004/05 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11
Year
Units
Our Vision
Our Strategic Themes
The key is constant productivity through innovation
DTCContinuousImprovementProcess
LEANIn theOffice
BusinessImprovementProjects
SuggestionsSix Sigma
Increasing Effort / Complexity for Implementation
2 EngineersBudgeted this FY227 Project ideas identified during R&D / Supplier workshop6-12 Months to ImplementPLM Process
1 Part Time Black Belt on loan (GWE)10 Green Belts (Part Time)10 Projects Identified this FY6-12 Months to ImplementDMAIC
3 Full Time HeadsCurrently 8 Part Time Teams and more planned FY1269 Projects under evaluation this FY6-18 Months to ImplementPM@Siemens
0.5 Full Time headCurrently 11 Part Time Teams Meeting Monthly105 Ideas Generated YTD3-6 Months to ImplementPDCA approach
0.5 Full Time headCurrently 15 Part Time Teams Meeting fortnightly294 Ideas Generated YTD3-6 Months to ImplementPDCA approach
0.5 Full Time headCurrently 290 Participants (70% of CNG)1,313 Ideas Generated YTD<3 Months to ImplementSimple Ideas
LEAN CellDesign
0.5 Full Time headCurrently 4 Projects Completed or Ongoing 43 Ideas Generated YTD4 Months to Implement4 Stage Prototype
Outputs from the Productivity Funnel
DTCContinuousImprovementProcess
LEANIn theOffice
BusinessImprovementProjects
SuggestionsSix Sigma
6 Projects started this FY>£100K Potential Identified YTD
8 Projects started this FY>£450K Potential Identified YTD
56 Ideas Implemented YTDAve Saving £5,336 per Team YTD
142 Ideas Implemented YTDAve Saving £6,194 per Team YTD
777 Ideas Implemented YTDAverage Saving £478.98 per Idea
YTD £161K Target £406K
YTD £617K Target £475K
YTD £195K Target £150K
YTD £0 Target £350K
YTD £312K Target £400K
YTD £8K Target £100K
* (YTD = End April 2011), including all productivity measures VAM, CRI & Cost avoidance. Excludes £430K roll over
Good Example.Designed new improved cover with less labelling and improved PCB together with new software and keypad with significant quality improvements Savings £42000/Yr
Good Example.A CIP team identified that one operator can now operates two PCB test systems at the same time instead of one system each.Saving £183,243/Yr
Good Example.A Material Handling LIO team identified that a saving could be achieved when ordering batches of 10,000 pieces instead of 1000 piece.Saving £29,412/Yr
Good Example.A third party supplier was used to customise our G110 drives for UK customer. By setting parameters inline we have eliminated the need for the third party.Saving £9,693/Yr
Good Example.An alarm to alert operators when pallet gets stuck at oven entrance, so that they can solve the problem rather than letting the pallets build up to a backlog situation.Saving £12,107/Yr
Good Example.Skiip’s are damaged upon power up if excess paste is applied during printing. 6 Sigma methods used to identify and reduce scrap.Saving £11,335/Yr
LEAN CellDesign
20 Ideas Implemented YTDAve Saving £6,750 per LCD Idea YTD
YTD £116K Target £170K
Good Example.VS2 LCD team on G110D production line have achieved reduction in floor space by 50% together with process improvements and WIP reduction Saving £81,944/Yr
34 Projects followed throughAve Saving £4,735 per Project
HigherEducation
SchoolEducation
Inte
rmed
iate
•Real skills shortage at technician level. Manufacturing will need at least additional 587,000 new workers over next 10 years mainly technicians
•Apprentice and technician route seen as second- class alternative to University
•40% of Engineering workforce aged > 45
•300,000 UK Graduates / year – only 10,000 engineering (China produces 600,000 engineering graduates)
•30% Engineering Graduates take careers outside of engineering
•Graduates often don’t have the right skills
•Poor perception of engineering and manufacturing•Too few student taking STEM subjects•Low skills and aspirationsNumber of 16 -24 year olds will drop by 8% in next 10 years
The UK Skill’s squeeze and challenge
National engagement Key Programmes
HigherEducation
SchoolEducation
Inte
rmed
iate
Gov
ernm
ent &
Min
ister
ial A
dvis
ory
Gro
ups
Man
ufac
turin
g In
sigh
t/Fu
ture
s
Sect
or S
kills
Cou
ncils
- Se
mta
Asso
ciati
ons
– CB
I / E
EF/R
oyal
aca
dem
y of
Eng
.
Prof
essi
onal
bod
ies
– IE
T/IM
echE
Educ
ation
al –
STE
MN
ET /
Engi
neer
ing
UK
E3 & Power Academy
Lincoln University
Diplomas/Apprenticeships
PM@Siemens Academy
Commercial Academy
Wind Power Maintenance
Schools & Ambassador pr.
LEAs and local agencies
Work placements
Diversity eg WISE
Individual Universities
Programmes; Big Bang etc.
Siemens approach to address ‘the squeeze’
Key Programmes
Primary
Enthuse
Secondary & 6th Form
Enlighten
Secondary & 6th Form(Colleges)Encourage & Engage
Undergraduate sponsorship
Engage
Apprenticeship
Engage
Graduate Recruitment
Engage
Workstream 1 Education / Schools
Workstream 2 Graduates
Workstream 3 Apprentices
1
2
Availability
Attraction and Recruitment
Make It
City
With Partner
Integrated in local business strategy
Sustainable
Employee Engagement
NGOCustomer
Others
Uses Siemens technology
Qualitative KPIsQuantitative KPIs
What
Who
How
Make It helps young people discover what manufacturing means and how it could lead to a rewarding and exciting career in the future
In our first Make It day 120 children from 10 local schools took part They are set challenges to 3 different problems and choose 1 to work on We provide the facilities and hospitability
Partnership with The Manufacturing Institute 6 Siemens managers acting as ‘Dragons’ Apprentices and graduates help the children on the day as ‘consultants’
Result98% of children felt it gave them a better understanding of the careers available in Manufacturing. In addition at the outset 52% said they would consider a career in Manufacturing at the end 82% said they would.
Girls can do it too!
City
With Partner
Integrated in local business strategy
Sustainable
Employee Engagement
NGOCustomer
Others
Uses Siemens technology
Qualitative KPIsQuantitative KPIs
What
Where
How
Siemens Motion Control in Congleton are encouraging girls and young women into engineering careers.
Events aim to increase the number of girls taking up engineering diplomas, apprenticeships and careers. Siemens has developed a program of factory tours, talks, events and competitions.
Primary and secondary schools with Siemens (plus other businesses) are working together in establishing a long term transferable model for the learning and skills sector.
Greenpower
City
With Partner
Integrated in local business strategy
Sustainable
Employee Engagement
NGOCustomer
Others
Uses Siemens technology
Qualitative KPIsQuantitative KPIs
What
Who
How
Greenpower is working with schools across the UK to encourage students to build and race their cars at motor racing circuits. Each race lasts for 4 hours so reliability, energy efficiency and innovation are key.
Around 600 schools and 10,000 students across the UK are taking part Targeting schools close to Siemens sites to increase participation Provide PLM software to all the schools participating
50 Siemens volunteers support the Greenpower events acting as stewards and marshals Apprentices and graduates help schools with the building of cars
Result Greenpower is monitoring the take up and success of students taking physics, maths and sciences to judge how effective the programme is improving student performance
Big Bang
City
With Partner
Integrated in local business strategy
Sustainable
Employee Engagement
NGOCustomer
Others
Uses Siemens technology
Qualitative KPIsQuantitative KPIs
What
Who
How
The Big Bang is the UK’s biggest single celebration of science and engineering for young people. Attracting over 23,000 students over three days from schools around the UK.
Siemens 4d ultrasound scanner on a phantom baby.Build a wind turbine model in actionPractical e-car building with Greenpower
20 Siemens graduates, apprentices and other employees volunteered to man the event for three days
ResultOver 58% of secondary pupils indicated that they were more likely to choose a STEM qualification.Siemens booth was voted in the top 10 attractions
The Urban Sustainablility Centre - London
Apprentices - Siemens plc works with national partners
Siemens Energy example• Siemens took apprenticeship
training in-house in 2008
To guarantee the quality of training provision to meet Siemens plc requirements
• Developed new Apprenticeship Framework for Wind Power Service Technicians
The E3 Academy
• Formed in March 2008 the E3 Academy offers three or four year sponsorship to undergraduate students studying Electrical (Energy) Engineering at the Universities of Nottingham, Bristol or Newcastle.
• This wide and exciting area covers Energy Conversion, Power Electronics, Machines and Generators, Electrical Drives and Control Engineering. This is a huge growth area with applications covering Aerospace, Automotive, Marine, Industrial Manufacturing, Renewable Energies, and Process and Utility Industries.
• Sponsorship is provided by UK-based international companies and the Academy is endorsed by the Institution of Engineering and Technology
• Academy Scholars will benefit from:• a bursary of £2,500 for each year of study. • 8 weeks summer vacation training paid at a rate of £1250 per month. • Academy events, such as the Summer School, where they will meet become acquainted with the Electrical Energy Engineering community. • If subsequently they are recruited by Siemens we pay them £6,000 back for tuition fees
Siemens Commercial Academy
• Alternative career to going to University – 3 Year programme with University day release (BA programme)
• Entry requirements:• B Grades (or above) in GCSE Maths & English• At least 240 UCAS points at A-Level (or equivalent) ideally in Maths,
Business Studies or Economics
Placements in different Siemens operating businesses• Accounting & Controlling• Supply Chain Management• Human Resources• Corporate HQ• Shared Services
• Key Focus areas
•
Move from reactive recruitment to proactive Increased use of academies, internships & sponsorship schemes (e.g. Power & E3 Academy). Recruit increasing proportion of our graduates through this approach – target 70% in 3 years Use local deliver centres/agencies to multiply our engagement e.g. Science Museums Develop better accreditation & development schemes (IET etc) Central pools of mobile Graduates Improved & targeted Branding & communications to Generation Y Fewer but closer Strategic University relationships and engagement
Graduate Activities
1
1 Generation Y – target group born in the 1980s & 1990s, see appendix for summary
Future Provision of Product & Graduate Training
A strategic initiative between Siemens and University of Lincoln
The first new purpose built engineering school in the UK for over 20 years
Commercial contracts and lease
agreements signed Steering groups formed Key staff appointments made Loughborough University
Mentoring
Planning application submitted April
2010 Links to Siemens Asia and NW Europe
made Awarded most “Responsible” project
within Siemens UK
World Class Facility - Lincoln
Over £7M of funding has been allocated to the construction of the new School of Engineering building.
The Hub will combine state of the art R&D ,teaching and training facilities, the building will make an iconic statement about the status and intent of Engineering at the University of Lincoln.
Forming part of the greater campus development, Engineering will take its place in a truly 21st Century University environment.
Key Benefits
Product Training Facility
Research & Development
Industry Ready Students
The demand is real!
*And finally……“Making things creates a need for design, infrastructure, production engineering and technological innovation that increases the technical skills base of the nation and creates employment and training opportunities of worth”
“A country of millions of helpdesk operators is not going to set the world alight. Value added to raw materials is more tangible that the parasitical commissions merry go round”
“Arthur Koestler drew an alarming parallel between the Roman Empire, with all the manufacturing processes sub-contracted to the provinces, and the idle, jaded citizens of Rome entertained by vile public spectacles, and the modern world…….and he had not even seen Big Brother or the Jeremy Kyle Show!”
* Taken from a letter to The Times 04/05/2011 Mr Stephen Hart in response to an Opinion piece by David Wighton
And finally……
Proud to be Siemens!
Proud to be a UK Manufacturer!!