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Lean In Vestas Nacelles Italy The Lean Manufacturing Journey
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Francesco Velluto
- VP Divisione Vestas Nacelles A/S
- AD Vestas Nacelles Italia – Taranto
- 49 anni, sposato, una figlia di 12 anni
- nel settore eolico dal 1990
- in Vestas dal 1998
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E siamo più di 20.000 dipendenti che credono nel vento
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Elisa Nicoletti
- PEX Manager
- 34 anni
- in Vestas dal 2008
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Content
1.Vestas: introduction to the company and its business
2.Vestas in Taranto
3.Vestas Journey through Lean Manufacturing
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Reaching our vision
Wind is…
Reducing green house gas emissions and climate change
Creating jobs and investment
Building energy security
Reducing dependence on fossil fuels
CO2
Introduction to the company
and its business
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We have installed close to 49,000 turbines in 73 countries worldwide spanning six continents 49,000
We monitor almost 25,000 turbines, or 43,000 MW, day and night and the data is used for efficient service planning and pre-emptive maintenance
25,000
We employ around 18,000 people worldwide from 85 nationalities and have more than 30 years of experience with wind energy
18,000
Vestas in brief
*Source: BTM Consult, 2012
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We are a truly global organisation
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55 GW amounts to 49,000 turbines, which generate enough clean energy to power over 19 million European households.
Vestas has installed just over one out of every five wind turbine MWs installed around the globe * *
Vestas has installed 55 GW of wind energy 65% more installed capacity than our closest competitor*
*Source: BTM Consult, 2012. * * Source 238 GW (at the end of 2011), according to the Global Wind Energy Council (GWEC).
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Our vision
Wind is…
Reducing green house gas emissions and climate change
On par with oil and gas
Building energy security
Reducing dependence on fossil fuels
CO2
Bringing wind on par with oil and gas Our aspiration, stated through our vision, is a society where at least 20% of the global
electricity supply is provided by wind.
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Industry leading track record in turbine development
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Vestas’ track record of turbine evolution over 30 years is unmatched in the wind industry
8.000
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… backed by performance guarantees
Superior service and certainty through:
the right PEOPLE, supported by
the right INTELLIGENCE, using
the right OPERATIONS AND MAINTENANCE plan,
the right INFRASTRUCTURE, maintaining
a strong PARTNERSHIP
Operation & Optimisation: Active Output Management Our commitment to you
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Safety comes first at Vestas
33% annual reduction of industrial injuries at
Vestas since 2006.
In 2012 there was record low 2.8 injuries per one
million working hours
In 2015, the target is 0.5 injuries per one million
working hours
Incidence of industrial injuries (per 1 million working hours)
25,3
20,8
15,6
8,1
5,0 3,2 2,8
2006 2007 2008 2009 2010 2011 2012
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Servicing throughout the wind project value chain Vestas is dedicated to working in partnership with customers to deliver the lowest cost of energy and maximum return on investment in wind energy.
Financing. Siting. Grid requirements. Local policy and regulations. Customers need to consider a wide range of crucial factors when they invest in a wind power plant. And not just at the planning stage, but for the whole lifecycle of the project.
Project planning
When customers choose a wind power supplier, they need a business partner with a track record of innovation, commitment and success of delivering wind power plants. A partner like Vestas.
Procurement and construction Operation and optimisation
Building a wind power plant is one thing. Operating it at optimum efficiency is another. Whether it is managing and maintaining the turbines, training customers to operate them..
Edit ”purple” bar to cover full cycle
Vestas in Taranto
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Vestas Nacelles Italia
Vestas Blades Italia
Vestas Italia
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Servicing throughout the wind project value chain Vestas is dedicated to working in partnership with customers to deliver the lowest cost of energy and maximum return on investment in wind energy.
Financing. Siting. Grid requirements. Local policy and regulations. Customers need to consider a wide range of crucial factors when they invest in a wind power plant. And not just at the planning stage, but for the whole lifecycle of the project.
Project planning
When customers choose a wind power supplier, they need a business partner with a track record of innovation, commitment and success of delivering wind power plants. A partner like Vestas.
Procurement and construction Operation and optimisation
Building a wind power plant is one thing. Operating it at optimum efficiency is another. Whether it is managing and maintaining the turbines, training customers to operate them..
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«Vestas journey through Lean Manufacturing»
La trasformazione Lean in Vestas
Le criticità e le soluzioni
I benefici per gli stakeholder
Lessons Learned
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Introduction of new tools, systems, organizations in
order to improve the company’s competitive position
in the market
1. Product Innovation
New Products (Technology R&D)
2. Process Innovation
Assemble at lower costs
Lean Manufacturing
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Principio della Riduzione dei Costi: PROFITTO = PREZZO DI VENDITA - COSTO
Approccio
Lean
Approccio
Tradizionale
Profit Profit
Profit
Costo
di
Prod
Costo
di
Prod
Costo
di
Prod Prezzo
di
Vendita
Prezzo
di
Vendita
VENDITE
Profit Profit
Profit
Costo
di
Prod Costo
di
Prod
Costo
di
Prod
Prezzo
di
Vendita
Principio del Valore Aggiunto: PREZZO DI VENDITA = COSTO + PROFITTO
Spreco
VENDITE
Prezzo
di
Vendita
Cosa vuol dire “Eliminare gli Sprechi”
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STABILITY
JIT
JIDOKA
Continuous
Improvement
Culture
Pull
Takt
Flow
QbD
Pokayoke 5S
Visual Management
Std. Work
The Lean Turbine
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Taranto Plant - 2007
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Make to Stock
Unbalanced Line
High Lead Time
High DoS
Big Warehouse
High WIP
High FG stock
High transportation
High motion
Supplier Factory
Customer
FG
Forecast Demand
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June 2007 - Taranto Factory – Assembly line Layout
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Warehouse
Warehouse
Assembly Line
Assembly Line
Warehouse
Warehouse
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“The Lean Journey in the Supply Chain”
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Current State
Specify Value
Identify Value
Streams
Create Flow
Leverage Pull
Seek Perfection
Lean Supply Chain
5 Principles of Lean
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Value Stream Mapping
• Preworkshop
• Current State
• Future State
Spread new culture
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Inventory Hides Problems
Raw Material Finished Goods
Company
Line imbalance
Poor communication
Poor scheduling
Quality Problems
Supplier delivery
problems
Poor scheduling
Poor 5S
Long set up times
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September 2008 - Taranto Factory – New Assembly Line Layout
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Warehouse
Warehouse
Assembly Line
Assembly Line
Warehouse
Assembly Line
Warehouse
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Lean in Vestas
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Percorso Lean in Vestas Nacelles Italia
Value Stream Mapping
Taktime
Da Make to Stock a Make to Order: PULL
100% personale formato
Bilanciamento della linea
50% riduzione Lead Time
91,5% Riduzione DoS
Supplier Factory
Customer
FG
FG
Forecast Demand
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Continuous improvement: Striving for Perfection
Continuous improvement journey.
Produce exactly what the client wants, when they
want it, and at the lowest cost.
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27 | Vestas sustainability department
Thanks for your attention