Lean approach on production lines Oct 9, 2014

Transcription

1 Oct 9, 2014 Dassault Mérignac 1

2 Emmanuel Théret Since sept : Falcon 5X FAL production engineer : chief project of 1st lean integration in Merignac plant 2010 : Falcon 7X FAL production engineer : flight test engineer (military inc. M2000H/TH & business aircraft) : Design office (Rafale FMS) 2

3 Content 1. Dassault production background 2. Lean : history and theory 3. Lean concepts implementation 4. Future developments 3

4 Dassault production background Dassault Aviation - Relatively small company ( employees) - Low takt time (production beat) - Edge of technical innovations - Highly customized products evolving in a moving environment : - Emergence of new requirements - Competitive world To survive : we have to do better than others in term of design and costs 4

5 Dassault production background ARP road map (ARP = improvement of production reactivity) to reach new standards of efficiency on production lines. Breaking approach which need basically a change of mindset : Projects implementation in different plants to build up a methodology for changing managing and organisation standards : generalisation to other parts of production and plants 5

6 History and Theory Frederick W.TAYLOR ~ 1890's ~ Scientific management Henry FORD : ~ 1910's ~ Standard products, Assembly line Taiichi OHNO : ~ 1955's ~ Wastes, Quality Just In Time, Recognition Evolution of different production system Oil Crisis ~ 1973 ~ TPS > mass production James WOMACK: ~ 1992 ~ TPS = Lean Manufacturing Today ~ Toyota most profitable manufacturer 6

7 History and Theory We have to optimise: Quality Cost Lead Time And need to improve safety and operators motivation BEFORE AFTER 7

8 Process perspective Supply chain and logistics Human organisation Lay out 8

9 Process perspective Supply chain and logistics Human organisation Lay out 9

10 Goal : organisation of work Methodology : 1. REAL FACTS (parts/duration/problems, wastes, ideas) : 2. Balance the workload on operators challenge standards of work Outputs : Standardised work sheets Working progress chart 10

11 Working progress chart 11

12 Process perspective Supply chain and logistics Human organisation Lay out 12

13 Principles : approach ideal vision water in pipes! right part at the right moment Tools : MIFD realize / simplify flows Results: Production in line pulled flows multi-products line Parts delivered daily regarding working progress charts Kanban delivery for some parts 13

14 Three different ways to deliver parts to the aircraft : kit trolley or Kanban delivery for small parts «Taxi mode» for big parts 14

15 Process perspective Supply chain and logistics Human organisation Implantation 15

16 Autonomous groups of operators Team leader Team manager (continuous improvement) Support teams (technicals/logistics/inspectors) ready to move and help! T.L. Tools : flash 5, QRDM, ANDON, Morning market 16

17 Flash 5 : safety working progress quality people - miscellaneous 17

18 Process perspective Supply chain and logistics Human organisation Lay out 18

19 19

20 Future developments Touch screen for working progress board ANDON Dassault Aviation s goal is to move by 2015 all production activities under lean manufacturing process and to focus on supports like: - Purchasing, - Design office (ergo conception) - Flight test center 20

21 QUESTIONS? 21