Hayward Tyler Group – Project 50Lanner Conference - MTCRoss Meikle & Oliver Buhlinger

Replace with global image

2

Hayward Tyler

:

What do we do?Design, engineer, manufacture & service electric motors for mission critical applications

How do we deliver it?Through:Continuous improvementOur peopleOur processes

How do we do it?Innovative product/service offering

Who do we do it for?Market led:Energy sectorGlobal customersLocal service

Leading manufacturer of ‘mission critical’ motors and pumps

High pressure, High temperature and Difficult to handle fluids

Where we are (incl. the number of our employees)

3© Hayward Tyler Group  PLC 2015 (www.haywardtyler.com)

219

25145

21100

6

4.

1.

2.

3.

5.

6.

Original Equipment design , project management and production centres

Local service centres

Locations:1 Luton, UK2 Peterborough, UK3 Glasgow, UK4 Vermont, USA5 Kunshan, China6 Delhi, India

4

Hayward Tyler Headquarters Development

:

Hayward Tyler Luton currently operates at £30million turnover Pushing through 80 units per year

The sites growth plan was to double to £60million by 2022Targeting a throughput of <160 units per year

Mix of Different Products

TO BE OUR CUSTOMERS’ NUMBER ONE CHOICE FOR THE PROVISION OF MISSION CRITICAL ELECTRIC MOTORS

5

Business Case

We opted to use simulation software to build on our pathway to achieving our vision and growth plan

The Sales team were given targeted growth planning per sector and number of unit increases

Showcase to potential customers that we will deliver 2-3 times our current capacity

Investors stipulation to use Simulation Software or there was no deal

6

Why Lanner Witness

Advised by Civil Nuclear Sharing in Growth (UK) Proven reputation in process simulation and optimisation

Case Studies showcased the company and softwareAble to provide us the usability we wanted with our model

Ability to transform our 2D into a 3D modelPartnerships with other ventures such as Virtalis

Able to connect with other software and databases

7

Where did we start

:

Analysis of products for Hayward Tyler Ltd

StatorRotor

1000+ components

8

‘Live’ Running Example

• Over to Oliver Buhlinger

- Start to finish example of 2D & 3D modelling of factory - What questions did the model answer for us• What do we want to model? Why?• How did we tackle this?• What was the result?

9

Parameters

3.1 Annual Target Rate (rotors & stators)Rate 70 per year

163

‘Live’ Running Example

Schedule2.1 ScheduleOrder Ref Product Type Product Desc Type Part Number Part Description Parent Level Op Seq Set Hrs Prod Hrs Total Hrs Resource Grp Subcon Hrs Out Operation Text

2 1 BCP 3 SP42878/011MOTOR AND TRANSIT ASSY 0 10 0 56 56 FITT 0 Build unit

2 1 BCP 1 SP42878_021

STATOR WIND & CONN *Q DRG 42878_021 ISS SP42878/011 1 30 0 2 2 FLASH 0 Flash

2 1 BCP 1 SP42878_021

STATOR WIND & CONN *Q DRG 42878_021 ISS SP42878/011 1 20 0 35 35 CONNECTING 0 Connect

2 1 BCP 1 SP42878_021

STATOR WIND & CONN *Q DRG 42878_021 ISS SP42878/011 1 10 0 110 110 WIND 0 Wind

2 1 BCP 1 SP42878_021_UF

STATOR ASSY PACK BUILD NB DRG 42878_2101 IS SP42878_021 2 110 0 2 2 WASH 0

Deburr and wash

2 1 BCP 1 SP42878_021_UF

STATOR ASSY PACK BUILD NB DRG 42878_2101 IS SP42878_021 2 90 0 3 3 WELD 0 Weld tie bars

2 1 BCP 1 SP42878_021_UF

STATOR ASSY PACK BUILD NB DRG 42878_2101 IS SP42878_021 2 80 0 3 3 WELD 0

Mark tie bar position

Preventative Maintenance (PM) Schedule

Wee

k

Day

BALA

NCE

BORE

CONN

ECTI

NG

FRAZ

E

LATH

E

WAS

H

WEL

D

WIN

D

VPRE

SS

GRIN

D

BRAZ

E

FLAS

H

FITT

CLEA

NING

CONN

ECTS

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 04 0 0 0 0 0 0 0 0 0 0 0 0 0 0 05 0 0 0 0 0 0 0 0 0 0 0 0 0 0 06 0 0 0 0 0 0 0 0 0 0 0 0 0 0 07 0 0 0 0 0 0 0 0 0 0 0 0 0 0 08 0 0 0 0 0 0 0 0 0 0 0 0 0 0 09 0 0 0 0 0 0 0 0 0 0 0 0 0 0 010 0 0 0 0 0 0 0 0 0 0 0 0 0 0 011 0 0 0 0 0 0 0 0 0 0 0 0 0 0 012 0 0 0 0 0 0 0 0 0 0 0 0 0 0 013 0 0 0 0 0 0 0 0 0 0 0 0 0 0 014 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1

2

Movements5.1 Table of movements

Ref ResourceGrpI D On, Off or Unused Cruiser On Rig 1 2 For

Production Off Rig 1 2movement

to next station

Crane Preference

1

Crane Preference

2

Crane Preference

3

Crane Preference

41 BALANCE Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 12 BORE Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 13 CONNECTING On TugOnly 0.05 TugOnly 0.05 TugOrCrane 14 FRAZE On TugOrCrane 0.3 0.05 TugOrCrane 0.3 0.05 TugOrCrane 15 LATHE Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 16 WASH Off TugOrCrane 0.3 0.05 TugOrCrane 0.3 0.05 TugOrCrane 17 WELD On TugOrCrane 0.3 0.05 TugOrCrane 0.3 0.05 TugOrCrane 18 WIND On TugOnly 0.05 TugOnly 0.05 TugOrCrane9 VPRESS Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 110 GRIND Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 111 BRAZE Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 112 FLASH Off CraneOnly 0.3 CraneOnly 0.3 TugOrCrane 1 113 FITT Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 2 314 CLEANING Unused CraneOnly 1 CraneOnly 0.5 CraneOnly 2 315 CONNECTS Unused TugOnly 0.5 TugOnly 0.5 TugOnly16 WELDS Unused CraneOnly 2 CraneOnly 1 CraneOnly 5 617 SPARES18 DYNO Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 2 319 TEST_OG Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 2 320 TEST_SUB Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 2 321 TEST_NUC_RCFW Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 5 622 TEST_BCP Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 5 623 PAINT Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 6 524 PACK Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 3 225 PACKBUILD On TugOrCrane 0.3 0.5 TugOrCrane 0.3 0.5 TugOrCrane 126272829 LAUNCHPARTS Unused CraneOnly 0.3 TugOnly 0.3 TugOnly 130 SubConReturn Unused CraneOnly 0.3 CraneOnly 0.3 CraneOnly 1

Resource Utilisation

Select Replication Average

11.1 Chart of Resource Utilisation %

9.5623.64

12.155.84

8.624.804.74

18.368.79

12.004.39

1.907.78

3.268.17

34.9075.09

32.3837.50

35.5939.8639.84

26.3035.25

31.5139.90

42.4336.86

41.4136.44

0.000.77

0.121.240.070.000.060.00

0.090.900.110.110.000.000.00

0.150.27

0.000.000.330.000.000.000.490.240.200.200.030.010.00

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

BALANCEBORE

CONNECTINGFRAZELATHEWASHWELDWIND

VPRESSGRINDBRAZEFLASH

FITTCLEANING

CONNECTS

busy

idle

blocked

setup

pm & broken

Wait for crane or tug

off shift

Daily ReportSelect Replication Average

10.1 Takt Time (hours)

10.2 Graph of Completed Pumps And Spares Output by Day

10.3 Total output 10.4 Table of Output by day Total Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

69 Total Quantity 0 1 1 1 1 1 1 2 2 2 2 4 4 4 4 4 4 5

85.2Takt

0

10

20

30

40

50

60

70

80

1 8 15 22 29 36 43 50 57 64 71 78 85 92 99 106 113 120 127 134 141 148 155 162 169 176 183 190 197Day

10

How have we utilized it

:

Customer interactionHT Luton – Mega Day (Communication Session)

Factory Layout 2D & 3D (Flow of Product)Purchasing Equipment (Borer, Lathe, Grinder, Tugs)Employee Engagement (Work Area Development)Investor Confidence in decision making processProven Our Layout Works with relatively low cost

11

Hayward Tyler Inc (Vermont) – Shop Floor Project

:

What if…Did it work…

Try this…

We have completed the current state model with the following to come:

Cell Based ModelsTemplates for input3D scanning of the shop floorImplementation of future state modelPhysical re-layout

12

Peterbrotherhood (Peterborough) – Shop Floor Project

:

We have completed the scoping phase with Lanner on the Peter Brotherhood siteOur next steps are:

Building a current state modelTemplates for input3D scanning of the shop floorAnalysis of current stateUnderstanding what the future state will look likeRun various scenariosImplementation of future state

13

HT Kunshan & HT India

14

Future Development

:

• Sales and Operational Planning at Hayward Tyler• What is it? How do HT use this?• Plug in FY17 model – (Live + High Confidence Level Orders)

• Utilizing the current templates in the current model developed

• Future Model• Initiating ERP information and templates into the model

• This will be utilised from a front S&OP perspective as well as day to day running on the shop floor with our live orders.

15

Thank you for listening to our story

: