Synchronised Production System

Synchronised Production System

SPS-LEAN & KAIZEN WORKSHOP

Intensive practice-oriented training with Japanese expert

/with translation into English /

Német-Magyar Képző Központ Egyesület |Felnőttképzési nyilvántartási szám 01-0676-04 Intézményi–akkreditációs lajstromszám AL 0105

Kaizen and lean in practice

The realisation of the synchronized production system is a decisive factor to ensure and extend the position of a company for a long term. The basics for the successful development of this system is the change from a pushing to a pulling production (pull-system), likewise the orientation at the principle of one-piece-flow. The central task within this is the contraction of the pass-through-time on all levels, which means an extreme reduction of circulating stocks and the extreme contraction of modification-time and the simultaneous raise of the modification-frequency. In the assembly the one-hand-modification, in the manufacturing the modification in cycle time is to be striven after. Another important aim of the synchronized system is the continuous re-duction of the manufacturing costs by permanent improvement of the proportion be-tween the human work and mechanical work. Mechanics and machine operators are step by step relieved and their productivity raised by developing themselves an inex-pensive and intelligent automation for single working steps, which are also simple to change (LCIA: Low Cost Intelligent Automation).

What is the workshop offering you?

Solutions

• for the change of existing production lines

• for concrete investigation and optimisation of product competitiveness • for balanced and high usage rates of the production lines being maximal flexible • for solid capture of production costs at the source

• for cost reduction in relatively high dimension

The participants learn methods, that will enable them to raise the productivity of the assembly lines significantly. Further they learn to standardise workflows in assembly lines, to reduce setting-up times, as well as how logistics and material flow can be distinctly amended.

Dr. Robert Keszte, Plant manager of the Central Electronic Plant in Timisoara of the workshop’s receiving enterprise /Continental Romania SRL/, about his expectations and the lean & kaizen effi-ciency:“ Lean means for me detail orientation, standardization, focusing on continuous improvement and hunting waste with the involvement of the entire organization.

I am a perfectionist minimalist. I like to do everything perfect with the minimum possible effort. And this is my way being lean. “

An effective method for success

Learning by doing - the immediately applicable knowledge comes to the house

This sophisticated practice workshop is performed in a local partner enterprise. The participants and the employees of the partner enterprise will with learning by doing get to know tools, which enables them to adjust single lines or even whole production areas to the synchronised production system.

At the beginning of the workshops the attendees get to know the theory about the human-oriented factory management, which is based on the slanting view and philosophy of Toyotas production methods (TPS). In the next step the participants can appropriate specific techniques in practice projects, with which it’s possible to create ideas being used for inexpensive and fast affectively implementation of solu-tions. Featured by the quick successes the attendees are decisively motivated. For the attendees the workshop implies at least 30 teaching hours of occupation in three days—between 8.00-17.00 h: mornings theory for the whole group, afternoons project work in teams.

The participants receive exclusive, with numerous descriptive illustrations enriched and supplemented, English or Hungarian (as requested) teaching material. This in-cludes the newest and current practice and research experiences.

Who should participate?

The workshop is approached to everyone being active in production and already hav-ing min. 3 years experiences with Kaizen or Lean, like: plant leaders, montage lead-ers, work preparlead-ers, manufacturing leadlead-ers, line persons responsible, master crafts-men, logisticians, planers, developers, calculators. The workshop is also addressed to those, who should, within the scope of the synchronised production system, develop a manufacturing point of view for working areas: constructors, developers, cost calculators.

Tetsuya Imura, after his natural science and mathematical studies he worked for the air force, where he developed him-self further in several technical sciences.

He worked for the Ueda-Eltric, later at Omrom Aso Co, where he engaged in production technology, QM, product development and process-improvement. Since 2005 he is head of the production technology department. Mr. Imura is specialist of Low Cost In-telligent Automation, and has clients in Belgium, Poland,

Slove-nia, LithuaSlove-nia, Italy, Germany as well as in Austria. He built

up the „One-Day-Delivery” system at his previous workplace: the system was able to deliver more than 13.000 products per day.

He is an emphasized practice-oriented expert, who has been

awarded different internal company-prizes for his process improvement work.

References: Arginta, Ceramtec, Dr. Schneider, Europal, Georg Fischer, Iskra, Nemak, PAW, Pintossi+C, Trelleborg

References in Hungary: Veritas Kft., Knorr-Bremse Fékrendszerek Kft., Phoenix-Mecano Kft.

Japanese-German-Hungarian Cooperation

The SPS GmbH is since 2004 a successful partner of the German-Hungarian Training Centre.

The 1997 founded SPS GmbH is working under the slogan

“The most flexible ones will be the first”.

Leading in the LEANing

With sales of €30.5 billion in 2011, Continental is among the leading automotive suppliers world-wide. As a supplier of brake systems, systems and components for powertrains and chassis, in-strumentation, infotainment solutions, vehicle electronics, tires and technical elastomers, Con-tinental contributes to enhanced driving safety and global climate protection.

Continental is also an expert partner in net-worked automobile communication. Continental currently has approximately 169.000 employees in 46 countries.

Continental in Romania

Through the end of 2011, Continental invested more than €575 million in its Romanian opera-tions. Both the Automotive Group and the Rub-ber Group, and all the corporation’s five divi-sions, are represented in Romania.

Continental has eight production units and three research and development centres in the cities of Timisoara, Sibiu, Carei, Nadab, Brasov and Iasi. Continental cooperates in a joint venture in Slatina and in a tire distribution centre for Eastern Europe in Săcălaz.

Continental currently employs over 10.500 people in Romania.

Workshop at Continental Automotive Romania Ltd.

Projects of the workshop

1. Pull & Flow introduction in production

2. TPM implementation in practice 3. Lean Clever Automation (LCA)

on an existing production line

4. Lean Clever Automation (LCA) for a new production line

5. Performance sustainability & Autonomous teams in production

References

• BOS Automotive Products Magyarország Bt.

• Bourns Kft.

• Eissmann Automotive Hungaria Kft. (2 times)

• FAG Magyarország Ipari Kft.

• Knorr-Bremse Fékrendszerek Kft.

• NI Hungary Kft.

• Phoenix Mecano Kecskemét Kft.

• Rosenberg Hungária Lég– és Klímatechnikai Kft.

• SMR Automotive Mirror Technology Bt. (2 times)

• Veritas Dunakiliti Csatlakozástechnikai Kft. (2 times)

• W.E.T. Automotive Systems Kft. (2 times)

• Knorr-Bremse Fékrendszerek Kft.

• Knorr-Bremse VJR Kft.

• Lear Corporation Hungary Kft.

• Leoni Hungaria Ipari és Kereskedelmi Kft.

• Loacker Kft.

• Mono-Ipolyfabric Kft.

• Mubea, spol. s.r.o.

• National Instruments Europe Kft.

• Nemak Győr Kft.

• Nordenia Hungary Kft.

• Pepperl+Fuchs Fém- és Műanyagipari Kft.

• PEX Hungaria Bt.

• Phoenix Mecano Kecskemét Kft.

• Profilplast Kft.

• Rafi Hungária Kft.

• Robert Bosch Elektronika Kft.

• Robert Bosch Power Tool Kft.

• Rohde & Schwarz Závod imperk s.r.o.

• Rosenberg Hungária Kft.

• Sämling Kft.

• SCS Stahlschmidt Cable Systems Magyarország Kft.

• SMR Automotive Mirror Technology Bt.

• Siemens Erőműtechnika Kft.

• Siemens VDO Automotive s.r.o.

• Temic Hungary Kft.

• TEVA Gyógyszergyár Zrt.

• Tyco Electronics Kft.

• Veritas Dunakiliti

Csatlakozástechnikai Kft.

• W.E.T. Automotive Systems Kft.

• WAHL Hungária Kft.

• ZF Hungária Kft.

• Zollner Elektronik Kft.

• Audi Hungária Motor Kft.

• AMB Components Hungary Bt.

• Balda Solutions Hungaria Kft.

• Balluff Elektronika Kft.

• Benteler Autótechnika Kft.

• BOS Automotive Products Magyarország Bt.

• Bosch Rexroth Pneumatika Kft.

• Bourns Kft. • Böllhoff Kereskedelmi és Szolgáltató Kft. • Bundy Kft. • Claas Hungária Kft. • Commerzbank Rt. • Contarex Agrotechnika Kft. • Continental Automotive Kft.

• ContiTech Rubber Industrial Kft.

• Datacon Kft.

• Detki Keksz Édesipari Kft.

• Dr. Oetker Magyarország Élelmiszer Kft. • DHL Express Magyarország Kft. • Eckerle Bt. • Egston Eggenburger System Elektronik GmbH • Eissmann Automotive Hungaria Kft.

• Epcos Elektronikai Alkatrész Kft.

• FAG Magyarország Ipari Kft.

• Festo-AM Gyártó Kft.

• Güntner-Tata Kft.

• Hammerstein Bt.

• Hajdu Autótechnika Ipari Kft.

• Hübner-H Gumi- és Műanyagipari Kft.

• IBIDEN Hungary Kft.

• IMS Connector Systems Kft.

• Kirchhoff Hungária Kft.

References

“I am glad, that the matter of the seminar was not just a transfer of knowledge like a pattern, but more characterized by a substance of mental realisation. The practical ex-ercises were fantastic possibilities: It was good to give our new ideas a trial. The work-shop was compounded by lots of new and old information. The professional preparation by the translator is to be pointed out. R. Bosch Elektronika Kft., employee

„10-37% of area-reduction, out-put improvement or stock reduction in three days. No-ticed new methods and theories like Best Point Theory and One-Touch-Tool-Change. New point of view of the management: Place the gauge high! Kaizen-Manager

“The matter, the lecture method and the practical intensity of the seminar was impres-sive to the experts of our company. The matter and the number of practical exercises were in the projects different, it was possible to gain knowledge from different points of view. The attendees were differently educated and had different experiences, but everyone could find a fitting role for him- or herself. On this way the groups also got to know the agonizing part of Kaizen. They fought with teambuilding, fast collection and order of information, the assessment of ideas and with the labyrinth of realisation. To-day in Hungary there’s a SPS and a Kaizen-Culture, wherefore it’s important to learn from each other and to control the development direction. For progress we need to turn to the Japanese, whose are traditionally using these methods. In these three days we got many small suggestions from the attendees and from the lecturer. This ideas are helping use to improve and synchronise the processes.”

Péter Stasztny - Kaizen Manager / Visiocorp KG. (currently SMR Automotive Bt.)

„That was the best thing on the workshop: realize the power in the team and use it to solve problems.” Péter Kerékgyártó, Eissmann Automotive Hungaria Kft.

“The illustrations with the help of example out of everyday life by a representative of a less known culture was refreshing for us.” Visicorp Bt. (currently SMR Bt.) employee

„I had the opportunity to recognise, acquire other approaches and use them in the practice.” Balázs Czeiter, Veritas Dunakiliti Csatlakozástechnikai Kft.

„A can use the practical and theoretical knowledge of the praticipants from other companies at my own business also.” Zoltán Rehus, Continental Automotive Hungary Kft.

“For me was the SPS workshop very useful: on the presentation I could see and hear plenty of good and practical examples and instructive solutions. For most the prob-lems we could find the solutions with very simple tools and methods. The guest par-ticipants gave us lot of good ideas, and revealed the problems from other perspectives. With the rearrangement of the storage we spared 20 % store area what is useable now for our new projects without a significant investment.”

Education type

Together a house-internal and an open seminar, because beside the employees of the receiving company, employees from other enterprises are joining the workshop.

Time and date

12th_-14th _{of November 2012 — (3 days) — (8.00–17.00 h)}

Continental Automotive Romania SRL / Timisoara, Siemens street 1.

Language

Japanese, with English translation

Costs and discounts

• In case of check-in to 26th _{October 2012: 300.000 Ft + VAT/person (1070 euro)}

• The companies who sent already colleague or were already local of a workshop: 300.000 Ft + VAT/person (1070 euro), them 280.000 Ft + VAT/person (1000 euro)

—in case of 2 participants and this is independent from the date of check-in

• If a company send two or more persons: 300.000 Ft + VAT/person (1070 euro)

• The full price of the training: 370.000. Ft + VAT/person (1320 euro)

The euro price is a gross amount and applies to companies from Romania and other countries – except from Hungary.

The participation fee includes the teaching material and other training related costs.

Deadline for announcement 5th November 2012

Certificate

The participants receive a confirmation of participation from the SPS GmbH and from the German-Hungarian Training Centre.

Conditions of participation

The number of participants is limited, so we please you to announce early. You can send the announcing form back to us via post, fax or e-mail.

Cancellation policy

Please appreciate, in case of cancellation we charge the following fees:

• between 7th-14th day before the beginning day of the workshop: 25 % of the full-price participation fee

• between the beginning day of the workshop and 6th day before beginning day of the workshop: 100 % of the full-price participation fee

Of course you can name a replacement participant. Not drafted services and supplies can not be compensated. The Training Centre reserve to itself to cancel the seminar until the 5th _{of November 2012. Already paid fees will be refunded then. The}

partici-pant does not have further demands. Cancellation is accepted only in written form, without a written cancellation the full-price participation fee will be billed.

Journey and accommodation: Arrival and departure, as well as accommodation are to be organized and paid by the participants. If you wish, the employees of the Train-ing Centre can recommend you nearby hotels and pensions.

Further information and registration Éva Márta Skultéti, Training consultant

Telefon: +36 1 243-3596; Mobil: +36 20 282-0107 E-mail: [email protected]