Galician Automotive Cluster

LAI MIT Annual Meeting 2010

Galician Automotive Cluster

Lean Production System

Our Sector’s approach to Excellence

Abel Tintos
Competitiveness Observatory / Image & Communications

Dana Point, CA – March 24, 2010.

Contents Galician Automotive Cluster

01 The Cluster: Critical Mass / History

02 Lean Roadmap

03 Program Description

04 Structure / Organization
g

05 General Scheme

06 Participating Companies

07 Deployment Results

08 Lean Experts Development Program

09 Follow-up: Lean Development

10 Sensei Support

11 Designing the Future:

CEAGA Corporate University

2
01 Galician Automotive Cluster

AN IMPORTANT CRITICAL MASS

CLUSTER VISION: ƒ 1 car manufacturer

To position the Galician Automotive ƒ 80 component suppliers

Sector as a European Leader in terms
ƒ Technological Center
of competitiveness and sustainability,
contributing
g to the p progress
g and q
quality
y ƒ Employment: 21,700
21 700 direct employees
of life of its environment. (10% of the industrial employment in
Galicia)

Around 30,000
30 000 employees if we take
into account the indirect employment.

ƒ Turnover: 8,400 million Euros

(
(equivalent
i l t tot 14% off th
the GDP in
i
Galicia)

ƒ Exports: 35% of the total exports in

G li i
Galicia
01 Galician Automotive Cluster

HISTORY OF THE GALICIAN AUTOMOTIVE CLUSTER

1997-98 1999-2000 2001-2002 2003-2004 2005-2006

Great cooperative culture

Excellence System 100% involvement

Scholarship programmes
Benchmanager for graduates
Networking actions
B2B platform Engineers’ programmes

Beginning of joint work Calibration Map Joint purchasing

1st working groups
CEAGA’s creation
University agreement
38 component suppliers Grouped training
5.800 employees Occupational training
PSA Pilot Centre research
I Automotive Master
PSA exceeds 2.000 veh/day
Recent Milestones…
2007-2008
2007-2008
CEAGA
CEAGALean
LeanProduction
Production Development of the CEAGA
System
SystemDeployment
Deployment
Energetic Excellence
Plan ISO TS 16949 Strategic information
Pathologies research
Inverse missions
II Automotive Master
Sectorial Excellence
IT projects
CTAG’s inauguration
g Sectorial Communication
Joint Logistic projects
Modulation research CTAG’s consolidation
Human Resources Cluster Car and exhibition
sectorial table Executive Auto MBA
R&D&I Plan to extend internationally
CEAGA-PSA’s Coop.
cooperative proyects International image
PSA chairs CTAG
Sectorial Coordination Investment attraction
PSA Convergence Plan Strategic Plan
2009 PSA new Picasso C4
Corporate University
 02 Galician Automotive Cluster

LEAN ROADMAP

Conference:
CULTURE

Experts in
Cultural
Change
STRATEGY

Leadership by
CEAGA at
maximum level
Management Employees and Lean Indicators
social agents Control Panel
EXECUTION

Awareness
awareness by CEAGA Annual
Conference: Mondariz.
Visits to companies Results Novembre 16-17,
Lean Diagnosis Sensei support SPLC
with Lean
deployment
p y + Action Plan at CEAGA Referential 2007.
LEAN PProgram
PEOPLE

Training of Training in Launchment

technicians and advanced
managers tools
COMPANY

Practice
exchange
workshops

2008-10
03 Galician Automotive Cluster

CEAGA LEAN PROGRAM

Objective: To support companies in the Lean transformation process

INDIVIDUAL ACTIONS JOINT ACTIONS

In-company training Joint training
Current situation diagnosis Experience exchange sessions
Action plan as a result from the diagnosis Annual Conference
Support in the deployment of the action plan Follow-up
Follow up activities

SUPPORT: SPECIALIZED CONSULTING Experience Exchange among Companies

COORDINATION: CEAGA
04 Galician Automotive Cluster

Structure / Organization of the Lean Program

Steering Committee LEAN CEAGA

• Coordinator: Pierre Ianni – General Director PSA PEUGEOT CITROEN VIGO CENTER
• Advisors: Francisco Anguera - President CEAGA – General Director GRUPO COPO

Members

• Paolo Etzi - Director DENSO SISTEMAS TERMICOS ESPAÑA

• Juan Antonio Lloves - Director GKN DRIVELINE VIGO
• José Carlos Rodríguez – Director FAURECIA AUTOMOTIVE
• Fernando Aramburu – Director GESTAMP VIGO
• Juan Antonio Muñoz-Codina – Director PSA PEUGEOT CITROEN PORTUGAL CENTER

These companies have been selected based on their level of Lean

performance and represent a reference for the others.
 05 Galician Automotive Cluster

General Functioning Scheme: Support the transformation process

Analysis Planning Execution

Action plan
Diagnose per Deployment of the action plan Specific
Training per
company in each company Training
company

Lean
Deployment 1st. Phase: July 2008 - … Deployment 2nd. Phase: November 2008 - …
Companies

Main Consulting Firms: Specific Consulting Trainers

Kaizen Institute, Valessentia,

Group
p training
g+
A i C
Amie Consulting,
lti A
Asenta
t
In-company Training
Consulting, Etc.

Joint actions coordinated by CEAGA

J i t
Joint W k h
Workshops – S t
Sector S t
Sector
Annual Meetings
training Best practices Diagnose Action Plan

LEAN EXPERTS TRAINING PROGRAM SENSEI SUPPORT BY CEAGA

06 Galician Automotive Cluster

Participating companies in the CEAGA Lean Production System

• 37 companies participating (12 SMEs)

• More than 85% turnover in the Sector
• 76% of the employment
07 Galician Automotive Cluster

CEAGA LEAN PROGRAM: DEPLOYMENT RESULTS

37 participating companies – 12 SMES

1st. Panel of Companies (2008) 2nd. Panel of Companies (2009)

28 enterprises (7 SMES) 9 enterprises (5 SMES)

85% of the turnover and 76% of the automotive components industry employment

Awareness Seminars: participation of 70 managers of 34 companies

412 managers and coordinators trained in-company

28 diagnosis and action plans carried out

9 di
diagnosis
i andd action
ti plans
l iin execution
ti

Sector Benchmarking – quantification of the individual / sector competitiveness level

Lean Auto
Auto-diagnosis
diagnosis – level of deployment / scope of action (qualitative)
08 Galician Automotive Cluster

Lean Experts Development Program

Objective: To train the persons that will coordinate the Lean deployment in their organizations.

INNOVATIVE CHARACTER

GENERAL MANAGEMENT SUPPORT BELTS: FOUR LEVELS

In-company implementation of the Introduction –white belt

contents studied in class and Junior –orange belt
accreditation of the personal
knowledge level as well as the real Senior –blue belt
deployment. p –black belt
Expert

THEORY – PRACTICE FOCUS EVALUATION BY PHASES

08 Galician Automotive Cluster

Lean Experts Development Program

NEXT BEGINNING
(Introduction, Junior and Senior)
APRIL 2010

D
P

on System
EXPERT C

First promotion: P
D
A
June – Dec. 2009 Formalización
Diploma
SENIOR C
conocimientos

AGA Lean Productio

f t A3
en formato

First promotion: P
D

June – Dec. 2009

A A3
Formalización
Diploma
JUNIOR C
conocimientos
en formato A3

P
D
A
A3
Formalización
C Diploma
conocimientos
INTRODUCTION en formato A3

A A3
Formalización

CEA
Diploma
p
conocimientos
en formato A3

A3

IMPROVEMENT OF COMPETITIONS PROGRAM

08 Galician Automotive Cluster

METHODOLOGY
Lean Training Model

Training
g in g in workshops
Training p
concepts

P D

Process and Level test

Results Audit C

Commission n
A

Validation
Individual
workshops Diploma

C
V
JUNE - DECEMBER 2009
• Two first levels: Introduction / Junior
• 104 hours of theoretical-practical training
• 52 hours of in-company coaching
• 25 students of 13 companies
• Cost per level of 50.000€ (for a group of 12 students)
• Per company (depending on the level of grants): ranging from 0€ to 2.500€ per
student
 09 Galician Automotive Cluster

Report: Follow-up Lean Deployment in the Sector

CEAGA Lean Control Panel:

• BenchManager tool, developed by CEAGA

• It represents 60% of the turnover an the employment of the components companies at CEAGA
• This is a tool that quantifies the particular level of competitiveness
• 25 indicators (customer quality, performance, breakdowns, absenteeism, etc.)
• Particular report per area (Quality, Production, Logistics, etc.)
• Annual basis – 2010 is the 7th. edition
• Individual Data – CEAGA Lean Control Panel

10,26%

6.000
120.000 2
99.617 2
5.271 €/m
99.617 4.954 €/m
€/empleado
€/ employee 5.000 6,65
6,65 7,30%
7,30%
100.000
77.779 hours/ employee
horas/empleado
77.779
€/ employee
€/empleado 4.000
80 000
80.000

3.000
60.000

40.000 2.000
1,28
1,28
hours/ horas/empleado
employee
20.000 1.000

0 0
Added value / employee Added value / production surface Training index in Lean tools Perons in Lean Projects
 09 Galician Automotive Cluster

Results: Level of Lean Deployment (Auto-diagnose)

Culture
100
Balance of production Communication
80

Pull system 60 Continous improvement

40
Vi su a l sy st e m s
20 100
TPM Visual systems
0 B a l a nc e of pr oduc t i on Or g a n i z a t i o n j o b si t e ( 5 s)
80

60

SMED Organization job site (5s)

40
P u l l sy st e m S t a nda r di z a t i on of f unc t i ons

20

Andon Standardization of functions

0

Poka yoke Operations

2007 2008
TP M Ope r a t i o n s

Lean Evolution – Level of Deployment

S M ED P ok a y ok e

A n d on

2007 2008

Lean Evolution – Level of Extension

10 Galician Automotive Cluster

Sensei Support: Personal coaching for companies

Giancarlo Destefanis
40 y
years of expertise
p in the Automotive Industry
y & Excellence in Operations
p

• To help companies in the development of their Lean Programs, an expert is

sharing
h i hishi vastt experience
i under
d the
th “Sensei”
“S i” figure.
fi

• He works personally with the Sector to boast the Lean Production System
implementation.
 11 Galician Automotive Cluster

CEAGA Corporate University: Uniting to Cooperate and Compete

MISSION A UNIQUE PARTNER

To serve as a vehicle to
accomplish the objectives pursued
by the Galician Automotive Sector
through the development of its
persons, guarantying the
competitiveness based in
innovation, technology and
knowledge.
DESIGNING
THE FUTURE MISSION
LAI enables the focused and
accelerated transformation of
complex enterprises through
collaborative stakeholder
engagement in developing and
institutionalizing principles,
processes, behaviors, and
tools for enterprise excellence.

EDUCATION AS OUR MOTOR OF CHANGE

Fostering the evolution of the Galician Automotive Sector on all levels of the value
chain… Change based on education and knowledge.
 Galician Automotive Cluster

Thank you!
y

For further information:

CEAGA - Cluster de Empresas de Automoción de Galicia

G li i Cluster
Galician Cl t off Automotive
A t ti Companies
C i

Abel Tintos
Competitiveness Observatory / Image & Communications
abel.tintos@ceaga.com

Avda. Citröen, 3 y 5
Edificio Zona Franca 1a. Planta - 36210 Vigo, España
Tel: (+34) 986 213 790 Fax: (+34) 986 214 761
Web: www.ceaga.com