lean in henkel adhesives, europe -...

Lean in Henkel Adhesives, EuropeVladimir Martinenko, Manager Lean Enterprise Europe CEE South &

Central Asia and Caucasus

1. Kaizen Congress in SerbiaBelgrade, 28th of Sept. 2017

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Agenda

1. Did you know about Henkel…

October 2, 2017

2. How Continuous Improvement programs work in Henkel...

3. What does it mean to be Regional Lean manager...

333

… that Henkel is the world's number one adhesives producer?… that Henkel sells detergents for around

25 billion wash loads per year?… that every second, more than 20 hair colorants from Henkel are sold worldwide?

October 2, 2017 1. Kaizen Congress in Serbia, Belgrade

Did you know…

444

Who we areLeading positions in consumer and industrial businesses

Adhesive Technologies Beauty Care Laundry & Home Care


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Who we areHenkel at a glance 2016

October 2, 2017

1 Adjusted for one‐time charges/gains and restructuring charges.

More than 50,000employees from 123 nations

42% of our sales generated in emerging markets

More than 140 yearsof success

€3.2 bn adjusted1 operating profit (EBIT)

171 manufacturing and 22 major R&D sites around

the world

Around €18.7 bn sales, +3.1% organic sales growth

1. Kaizen Congress in Serbia, Belgrade

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• Our sustainability strategy: Achieving more with less

• Ambitious long-term goal for 2030:Triple value in relation to our footprint (Factor 3)

• Interim target 2010 – 2020: Increase our overall efficiency by 75%

• External recognition: Leading positions in various national and international sustainability ratings and indices.

What guides usLeadership in sustainability


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Status of our sustainability targetsOur progress toward our long-term goal “Factor 3”

October 2, 2017

1 Compared to the base year 2010.2 Waste footprint of our production sites, excluding construction and demolition waste..


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Henkel Plant in InđijaHenkel Plant in Inđija

Henkel Srbija

Administrative centre in BelgradeAdministrative centre in BelgradeHenkel plant in KruševacHenkel plant in Kruševac

2002. 2008. 2007.


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Key Developments

October 2, 2017

1924Name changed to “Merima”, largest soap producer in Balkan region

1924Name changed to “Merima”, largest soap producer in Balkan region

1839Founded as soap & candles factory

1839Founded as soap & candles factory

1961Powder detergents production established

1961Powder detergents production established

1927Cosmetic production started

1927Cosmetic production started

2002Bought by Henkel; new name: “Henkel Merima”

2002Bought by Henkel; new name: “Henkel Merima”

1970First cooperation with Henkel

1970First cooperation with Henkel

2007Adhesive production moved to Indjija

2007Adhesive production moved to Indjija

2004Production of building adhesives started

2004Production of building adhesives started

2011Name changed to Henkel Srbija

2011Name changed to Henkel Srbija


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Henkel SrbijaIzvozi na 35 tržišta

•Albanija•Austrija•Bosna i Hercegovina•Bugarska•Hrvatska•Mađarska•Makedonija•Nemačka•Crna Gora•Poljska•Rumunija•Turska•Ukrajina•I druga

55 miliona potrošača


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Agenda

1. Did you know …

October 2, 2017




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Development of Lean Manufacturingfrom the KAIZEN- era at Toyota to HENKEL today

HPSHenkel Production System

1950 1980 1991 1992 since1998

2007-2008

2006since1997

20132003

KAIZENera starts at Toyota

2014

KAIZEN translated intoEnglish

Recognition of productivity differences ofup to 40% betweenJapan and Europe/USA

Start of KAIZEN in the Western world

Confirmationof the success factors and methods in various industries

Different Kaizen activities Louviers Düsseldorf Winsford

Introductionof “Site Excellence”

Introductionof “TOPP”inHeidelberg

Roll out of“g4e”DüsseldorfDublinHannover

Roll out of“g4e”MontornésSchönbachCaleppioCasarileCeranoScheemda

Integration of SixSigma in „g4e“

2009-2011

Global Alignment of Continuous Improvement Initiatives & StandardsinAdhesives Operations (AO)

Introduction „Lean Enterprise“inAO Global

future

Alignment of A&B&L

Trans-formationto Henkel Production system „HPS“

Since 1998 Henkel

successfully implements

Lean principles


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Today

Henkel Production SystemAligning A, B, and L Across Henkel

Future

HPSHenkel Production SystemCreate a standard operating system for the Henkel Supply Chain and Operations based on Lean principles that will accelerate performance improvements and create customer value

L

A

Lean Enterprise

B

1. Kaizen Congress in Serbia, BelgradeOctober 2, 2017

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Standards

• Standardized work

• Visual management

• 5S

• Risk based project selection

• Value stream mapping

• CI workshops

• Problem solving

• Quick changeover

• Autonomous maintenance

Henkel Production SystemStandards


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Standards

• Control Plan

• Error Proofing

• Management of Change

• Statistical Controls

• FMEA

• OEE

• Six Sigma

• Pull System

Henkel Production SystemStandards – Additional in Adhesive Technologies


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Who we areAdhesive Technologies

€8,961 msales

+2.8%organic sales growth

€1,629 m adjusted1 operating profit (EBIT)

30%innovation rate2

>80%of our sales generated with our top 10 brands

1 Adjusted for one‐time charges/gains and restructuring charges.2 Percentage share of sales generated with new products launched onto the market within the last five years.


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PortaWestfalica

Hannover

Tallaght

Ballyfermont

Winsford

WesterloAntwerpen

Montornes

Schönbach

Heidenau

Düsseldorf

Bopfingen

Scheemda

Villefranche

Unna

Erlinsbach

Casarile Caleppiodi Settala

Zingonia

NorrkopingPärnu Tartu

Valkeakoski

Zaslavl

Staporkow

DzierzoniowHeidelberg

Környe Oleshky

Vysgorod

Balakleya

CampiaLviv/Mikolaiv

Rosnov

Pantelimon

Mirovjane

Indjija

Engels

Tosno

Kolomna

Uljanovsk

Chelyabinsk

Drogenbos

> 10051 – 100< 50

Headcount per Site

Adhesive Technology Plants Europe (52 Plants)

Bileca

Wrzaca

Stavropol

Tbilisi (Georgia)

Novosibirsk

Kapshaghai (Kazakhstan)

Wehr

Norderstedt

Epernon

St. Neots

Hernani


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Lean Enterprise Europe - Management Team


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Why?

• We want to coach, train and develop people

• We want to improve all key metrics

How?

• We want to establish a system of improvement based on lean principles and involvement of all employees

• We want to focus on waste elimination to generate customer and shareholder value

How we are doing Lean?Objectives of Lean Enterprise Europe


202020

Henkel Production SystemTie-in to Overall Strategy – End-to-End Supply Chain


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LE Europe 2016: Short facts

Team lead: 1 Workforce: 8 Sites in Europe: 52

3 Six Sigma trainings

+ support in 460 additional local workshops

50 workshops

workshops in 26 sites

444 travel days

14%

82%

4%

Workshops

VSM

CI WS

Invest

> 1500 participants reached


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Impressions of Lean workhops

October 2, 2017

„It was a great workshop across businesses.“

AM & HPS leadership workshop, Krusevac (Serbia) QCO workshop, Heidenau (Germany)

VSM workshop, Villefranche (France)Liofol workshop, Düsseldorf (Germany)

„Significant productivity increase and space reduction possible: 2 floors instead of 3.“

„The target on productivity increase by 10% can be reached by the improvements found.“

„Time variances of 25% - Why does everyone do it so different?”


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Agenda

1. Did you know …

October 2, 2017




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What does it mean to be Regional Lean manager?

Knowing different people andTechnologies

Sharing of Best Practise

Good ratio between physical and virtual meetings

Intensive usage of new ways of communications, networks…

Recognition – taking them out of their normal work

Celebrating small wins

Actions and Result belong to local team!

Work not harder, but smarter and safer

Knowing different people andTechnologies

Sharing of Best Practise

Good ratio between physical and virtual meetings

Intensive usage of new ways of communications, networks…

Recognition – taking them out of their normal work

Celebrating small wins

Actions and Result belong to local team!

Work not harder, but smarter and safer

Different sub-culture

Way of leadership

Language barrier

Travelling (time, money…)

Virtual meetings

WIIFM

Additional activity - > overload?

Savings, savings, savings…

Different sub-culture

Way of leadership

Language barrier

Travelling (time, money…)

Virtual meetings

WIIFM

Additional activity - > overload?

Savings, savings, savings…

DIVERSITYper location, technologies, nation

LONG DISTANCES

Belgrade Novosibirsk

MOTIVATION OF PEOPLE

GEMBA, GEMBA, GEMBA...

EXPECTATIONS

DIVERSITYper location, technologies, nation

LONG DISTANCES

Belgrade Novosibirsk

MOTIVATION OF PEOPLE

GEMBA, GEMBA, GEMBA...

EXPECTATIONS


252525

AO Europe Lean Enterprise team

October 2, 2017

„Change is the only constant.“- Heraclitus


Thank you!

lean in henkel adhesives, europe -...

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