i- apsys ii- apsys tools & concepts iii- people · pdf fileii- apsys tools & concepts...

I- APSYS

Agenda

II- APSYS TOOLS & CONCEPTS

www.rsgbestpractice.org

III- PEOPLE DEVELOPMENT

http://www.railsupplygroup.org/


APSYS = ? ALSTOM Production SYStem

Mission:

“Implement a common way of working on all sites to fulfil the SQDC performance commitment with common, sustainable, effective processes.”

WHAT? APSYS Mission




• Eliminate waste

• Pull flow

• Make problems visible

• Create standards based on best practices

• Be involved in continuous improvement

The APSYS principles

are based on those of Lean Manufacturing ...

WHY?




WHERE? - The APSYS Network – Services

Haifa - Jerusalem (Israel)

0

Naperville (USA)

THOMPSON Jeffrey

Valle de Mexico

Ramirez Joab

Ridderkerk

Cabreuva (Brasil) 0

TOMINO Giselle Preston Bro (Sweden)

HOGGAN Laurence JONSSON Oskar

Manchester

MORRIS Jonathan

Dublin

Neptuno (Chile) 0

BURDILES-ARCE Jimmy Nottingham

0

Golders Green

HUNTER Lisa

Stendal (Germany) Algiers

MATERZOK Ralf (Acting) ABDI abdelhak

Le Creusot Braunschweig

MARQUES Carlos MOULES Jeremie (Acting)

Bucharest

RADU Mihai

Sesto (Italy)

PAFFETTI Alberto

Minuetto(Italy)

GATTI Andrea

Villeurbanne

0 La Sagra (Spain) Nola (Italy)

Tarbes MORA Pablo GRIFFI Paola

0

Apsys Leaders LIST - 2015-10.

Warsaw

PRUSAK Piotr




UK&I APSYS Leader Locations

PRESTON

MANCHESTER

GOLDERS GREEN

WEMBLEY




HOW? APSYS roadmaps by Domain

From a tool box to a true philosophy…

Wave 1Wave 8 Wave 11 Wave 14

Shop Floor

Supply Chain

Quality

Industrialisation

Management

Sourcing

Project (pilot)

2004 2012 20152009

Engineering (pilot)




I- APSYS

Agenda






QRQC : Quick Response Quality Control

• Tool Robust Containment

Deep Root Cause analysis : Ishikawa, 5 Why …

• Daily animation

• Mindset : • Gemba / Genbutsu / Genjitsu• Real place / real part / real data

Use of QRQC tool for every issue - in every department




SITE IMPROVEMENT PLAN




SITE IMPROVEMENT PLAN

SWIPSingle WeekImprovement Program




Production APSYS BOARD

Monitor our Performance during 5’meeting with relevant SQCD Indicators

Better Visible Management : performance / non-performance, problems are not hidden, forgotten !

Fix problems rapidly

Ensure TEAM responsibility, clarify responsibilities and accountabilities




Standardised Operations

• High Process variation depot to depot• Introduction Of Standard

operation sheets

• Best known way to complete task

• Standardisation across depots maintaining ;-• Safety

• Quality

• Delivery

• Cost




I- APSYS

Agenda






Lean Training Overview & Certification

• Three week training program :

• Wk1: Lean Toolkit

• Wk2: SWIP (Single Week Improvement Project)

• Wk3: Kaizen Instructor Training

• Certification

• Fulltime attendance on course

• Pass Lean Toolkit question paper (wk1) – 70% pass mark

• Successfully complete Lean project

A team embedded in each area of the business to act as

Ambassadors for Lean




Wk1 - Lean Toolkit Agenda

Day08:00 08:30 09:00 09:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 16:45 17:00

1 Lunch

Pulse

Check

Review

2Review

of Day 1Lunch

Pulse

Check

Review

3Review

of Day 2Lunch

Pulse

Check

Review

4Review

of Day 3Lunch

Pulse

Check

Review

5Review

of Day 4Lunch

Value Stream MappingBusines Process

Kaizen

Kaizen Breakthrough

Methodology

Total Productive

MaintenanceLean Value Chain

Review &

Test PaperProblem Solving

Training Overview

Previous cohort

Lean Facilitator

Project

Presentation

Policy

DeploymentManagement System

Plug game -

Simulation #1

Plug game -

Simulation #2

Lean Production System -

Part 2

Plug game -

Simulation #3

5S Workplace Organisation &

Visual Control

7-WastesLean Production System

- Part 1

Lean Facilitator Training - Week 1 Agenda

Set-up ReductionProcess & Time

ObservationStandard Operations Kanban

Plug game -

Simulation #4




Lean Training for Steering CommitteeStandard Agenda – 2 Days




Lean Training




Understanding the need for kitting Understanding the need for 5S Understanding the need for

Indicators

Understanding the need for 5’

Meeting

Understanding the need for

Autonomous teams

Understanding the need for Task

Sequence

+ 7 wastes, VSM, Improvement Plan, …

Lean Training - Tools covered




Next Phase – Lean Learning Organisation




APSYS Key Points

• Lean Manufacturing is not a tool box but a long-term philosophy.

• Lean Manufacturing seeks to satisfy our customers by producing with maximum added value (optimisation of processes) and consuming minimum resources (waste reduction).

• The motivation and involvement of people iskey to the success of Lean . Building a culture for success

• APSYS is the Alstom Production SYStem based in lean concepts.




Questions ?




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