THE SOCIETY OF MOTOR MANUFACTURERS AND TRADERS LIMITED PAGE 1

Carl Milbourne

Head of Operations

UYT

An overview of some successful methods and strategies

Carl Milbourne

Head of Operations

Attitude Innovation Heritage People Technology Agility

Corporate Profile or Heritage

600t Tandem Press

1800t Transfer Press

600t Blanking Press

200t Progression Press

Press Facility Overview

600t Progression / Transfer Press

Robot or Manual

Spot Welding = 220

Projection Nut Weld = 60

Automated Mig Weld = 8

Auto Nut Welder = 2

Weld Facility Overview

Accreditations

Evolution to Lean & Agile Manufacturing~

Volume & Investment Trend

Comment:- As shown UYT has had many New Model launches within a short period of time, each one pushing towards a more lean/agile manufacturing base.

Evolution to Lean & Agile Manufacturing ~ First big Milestone

2001

Door apertures

Sun roofs & panels

Tail gates

Bumper Beams

Front Side Frames

Front Damper Housings

Front Bulkhead

Rear Side Frames

Front & Rear Wheel Arches

Advantages: Linear line flow

Interchangeability

Strategy Brief:-

To expand our Weld

Facility by 25%, this

allowed us to increase our

welding capacity and also

accommodate more

complex Structural parts.

“Hang on Parts” “Core Comps” “Complete parts Range”

Evolution to Lean & Agile Manufacturing ~ Capacity Constraint's

2001

2004

2006

Advantages : Quicker cycle time

Increase Output

Flexibility of manpower

Strategy Brief:-

Volume increases

placed pressure on

existing line layout. UYT

increased capacity to

accommodate volume

flex.

Back to back production Front to Front production

2004

Evolution to Lean & Agile Manufacturing ~

Greater Press Portfolio

Advantages: Increase Product portfolio

Increase Output

Competitive Piece price

Strategy Brief:-

Greater press flexibility

was a key driver for

this phase. We

Expanded our Press Facility by 50%

2006

Evolution to Lean & Agile Manufacturing ~ Space Constraint’s

Advantages: Inventory Accuracy

Greater Buffer control

Strategy Brief:-

With the rapid volume

increases UYT

experienced logistical

space was an issue. It

was necessary to

create a ‘Bonded’

warehouse for Int/Ext

product

2010 Advantages Multi Variant lines

Skill Versatility

Floor Space Utilization

Strategy Brief:- Low Volume created an

Opportunity to increase the

flexible capability of our

Assembly lines. With Lines

being more efficient floor

space could be Utilised

towards our vision of “

Innovation line” basically

Benchmark line layout

Evolution to Lean & Agile Manufacturing ~

“Sowing the Seed”

2011 Factory Layout

2012

2013

Current Factory Layout

Evolution to Lean & Agile Manufacturing ~ Innovation Lines

Strategy Brief:-

Amalgamation offered the

opportunity to free issue

the use of equipment into

the new modular lines.

This reduced amount of

new investment required

(£12M)

Phase 1 Phase 2

Phase 3 Phase 4

Evolution to Lean & Agile Manufacturing ~ The transition……

2012

2013

Final layout

2015

2016

Evolution to Lean & Agile Manufacturing ~ Future Bottleneck

Advantages Remain Competitive

Reduce piece part cost

Potential to broaden

our customer range

Strategy Brief:-

OEM’s are driving for a

more efficient car through

weight saving’s. High

strength steels are

becoming an important

factor for this.

However they require

bigger tonnage Press.

3000Ton Press

2008

2011

2012

2013

2014

Tsunami

Thai floods

x 1 fire

UK Storms

Global Recession

Japan tsunami

Key Facts:- Extreme heavy rains in Thailand during

Sept & Oct. 2012. Most expensive natural

disaster in Thai history.

Significant Infrastructure damage

especially Industry.

Thai Floods

Key Facts:- March 11, 2011 - At 2:46pm, a 9.0

magnitude earthquake takes place 231

miles off Japan.

The earthquake causes a tsunami with 30 ft

waves that damage large area’s within

Japan.

Significant impact to Japan’s economic

infrastructure

Key Facts:-

Significant downturn in Global Economy

Sterling devalued by some 30%

Automotive industry heavily effected

(Luxury goods).

Things you don’t plan for…….

Recession

Response to change

“Its not the strongest of the species that survives, nor the most intelligent, but the

one most responsive to change”

2008

Auto Replenishment

Inspection method improvement

1st Line management development

TPM across Plant

Treat unplanned as an Opportunity to Improve-Back to Basics

Quality up activities Parts control improvements Upskill 1st line management

2011

Treat unplanned as an Opportunity to Improve

“ Stronger constitution”

2012

Training Room / Centre

5s on Genba 5’s on Genba

Created a safe working environment Gain ideas from the general associates Promote best practice

Flywheel Used to increase momentum and thereby provide greater stability or a reserve of available power

Mr Mayumi-san was a lone Nut

To Start a Movement :- Must be Public Easy to follow Embraced as equals It takes GUTS to be the first follow No movement without the first follower

UYT Gained Momentum We don’t want to stop this movement!

Manchester UTD

1999 – Won Champions league [Treble] Best team in the World

Attitude/Work Ethic Impact on the Business Skills Courage Irreplaceability

UYT Ltd ‘Class of 2002’

All above started UYT as General associates

Craig Tidman Operator Q /Mgr

Mark Sabino Operator P/Mgr

Dave Ward Operator E/Mgr

Vish Dhand Operator W/Mgr

David Jackson Operator Q/Mgr

Disturbance ” An interruption of that which is Normal or Regular”

Upset

Distraction

Worry

Distress

Interference Annoyance

Hassel

Disruption Irritation

Inconvenience

Trouble

Bother

When things go Wrong look into the mirror to see what you could of done better – Don’t portion blame on others When things go Right look out the window to give praise – Don’t bask in the glory

2014 Target Remove all Disturbance from the Genba No silo Management by Departments Strong Teamwork

The Story so far………………..

2012 2013 UYT

Flywheel Used to increase momentum and thereby provide greater stability or a reserve of available power

Mr Mayumi-san was a lone Nut

To Start a Movement :- Must be Public Easy to follow Embraced as equals It takes GUTS to be the first follow No movement without the first follower

UYT Gained Momentum We don’t want to stop this movement!

Manchester UTD

1999 – Won Champions league [Treble] Best team in the World

Attitude/Work Ethic Impact on the Business Skills Courage Irreplaceability

UYT Ltd ‘Class of 2002’

All above started UYT as General associates

Craig Tidman Operator Q /Mgr

Mark Sabino Operator P/Mgr

Dave Ward Operator E/Mgr

Vish Dhand Operator W/Mgr

David Jackson Operator Q/Mgr

Disturbance ” An interruption of that which is Normal or Regular”

Upset

Distraction

Worry

Distress

Interference Annoyance

Hassel

Disruption Irritation

Inconvenience

Trouble

Bother

When things go Wrong look into the mirror to see what you could of done better – Don’t portion blame on others When things go Right look out the window to give praise – Don’t bask in the glory

2014 Target Remove all Disturbance from the Genba No silo Management by Departments Strong Teamwork

The Story so far………………..

2012 2013 UYT

Thank you for

Listening

Don’t forget to Visit UYT stand (Stall 1)