DECIMO SALONE D'IMPRESA Carmine Vox
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1. The document discusses Bosch's approach to process management, including its core processes of product engineering, production engineering, procurement, production, and order fulfillment. 2. It provides an overview of Bosch's Order Fulfillment Process and its adoption of a BPS (Bosch Production System) approach. 3. The BPS aims to achieve lean production through principles, tools, and elements that empower workers to execute the principles, with the goal of achieving best-in-class status.
DECIMO SALONE D'IMPRESA Carmine Vox
- 1. Salone d‘ Impresa - Venezia 18.05.2012 The Bosch approach to Process Management Diesel Systems / Chassis Systems Control 1 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 2. Salone d‘ Impresa - Venezia 18.05.2012 BarP Process Model: Management Processes Change Strategic Management Management Core Processes (Value Adding Processes) Product Engineering Process Product (PEP) Development Production Engineering Customer Customer Order Fulfillment Process Procurement Production Delivery Support Processes Human Quality Health Safety IT Coordination Controlling Technical Plant Protection Resources Purchasing Management and and and Finance Functions and Security Management and Methods Environment Organisation Diesel Systems / Chassis Systems Control 2 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 3. Salone d‘ Impresa - Venezia 18.05.2012 Order Fulfillment Process: BPS approach Diesel Systems / Chassis Systems Control 3 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 4. Salone d‘ Impresa - Venezia 18.05.2012 The Bosch Production System: Targets ” True North” Best In Class Initial Ideal State Principles Eight general rules, that status describe the BPS philosophy • 0 failure Tools • One Piece Flow Empowerment in order to • in sequence execute the principles • according to demand • 100% added value BPS our success for Lean Production Diesel Systems / Chassis Systems Control 4 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 5. Salone d‘ Impresa - Venezia 18.05.2012 The Bosch Production System: BPS Principles Perfect Quality Process Orientation as Guide Line Flexibility Pull System BPS Elements for Value Stream Quick Change Q- Poka Kaizen- empowering Design Over Tools Yoke Workshop Consumption Ship to TPM Lean Line Design 6S Control Line Point Flow Oriented Cyclical Lay Out Leveling ... CIP Material Flow Diesel Systems / Chassis Systems Control 5 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 6. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 6 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 7. Salone d‘ Impresa - Venezia 18.05.2012 Since 2006: Pull System through TPM - TPM/5S Perfect Quality Process Orientation Definierte ä ne Visualisation Flexibility Pull System Value Stream Quick Change Q- Poka Kaizen- Design Over Tools Yoke Workshop Consumption Ship to TPM Lean Line Design 6S Control Line Gemeinsame Point Flow Oriented Cyclical Lay Out Leveling ... Aufr ä CIP Material Flow Aktionen an Wochenenden TPM TPM to stabilize the OEE of all bottleneck processes Diesel Systems / Chassis Systems Control 7 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 8. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 8 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 9. Salone d‘ Impresa - Venezia 18.05.2012 Since 2007: Flexibility through Material Flow Batch size for transport = 1600 Batch size for transport = 120 Perfect Quality Process Orientation Flexibility Pull System Value Stream Quick Change Q- Poka Kaizen- Design Over Tools Yoke Workshop Consumption Ship to TPM Lean Line Design 6S Control Line Point Flow Oriented Cyclical Lay Out Leveling ... CIP Material Flow Cyclical Material Flow Frequency transportation allows continuous stock reduction Diesel Systems / Chassis Systems Control 9 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 10. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 10 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 11. Salone d‘ Impresa - Venezia 18.05.2012 Since 2008: Transparency through 5S + Safety = 6S Perfect Quality Process Orientation Flexibility Pull System Value Stream Quick Change Q- Poka Kaizen- Design Over Tools Yoke Workshop Consumption Ship to TPM Lean Line Design 6S Control Line Point Flow Oriented Cyclical Lay Out Leveling ... CIP Material Flow 6S 6S as must for BPS Diesel Systems / Chassis Systems Control 11 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 12. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 12 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 13. Salone d‘ Impresa - Venezia 18.05.2012 Since 2009: Associate Involvement - empowering the entire organization Training for Managers Training Top Down Shopfloor PM Shopfloor Training Bottom Up Management VSMgr Management Cycle Cycle Department Leveling and Manager Standards for Pull TeCo and Groupleader Tele Training for Teamkoordinater, Planer, Planer Teamleader Standards at Shopfloor for Workers workers Training, involvement and motivation as success factor Diesel Systems / Chassis Systems Control 13 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 14. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 14 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 15. Salone d‘ Impresa - Venezia 18.05.2012 Since 2009: Associate Involvement Management as Mentor in daily work Targ et Management Top Down: - Development of the Vision - Mentor - Mentee - Support employees to Management Bottom Up: find solutions - Release of resources - Target setting Management Associate I Know it I do it I Lead it I teach it Diesel Systems / Chassis Systems Control 15 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 16. Salone d‘ Impresa - Venezia 18.05.2012 BarP BPS success story: From System Leaders CIP to Training as Point CIP program for Mentor • Lean Admin Reinforce all leaders Review 5S and workers Training on • Training Cyclical shop floor: blue collar: System CIP Material Training on • Planners • Quick to Point shop floor: CIP, Flow • Pull-system • Working Change Leveling TPM stabilisation According Over • System CIP • Ship to Line to Standard • VSD Vision to Point roll-out • Shop-floor • CIP in al CIP • Reinforce Manage- • Integration direct areas bottom-up ment Cycle BPS-CIP • Cyclical Material processes • CIP on shop floor Flow • Linea Gialla 2006 2007 2008 2009 2010 2011 Diesel Systems / Chassis Systems Control 16 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 17. Salone d‘ Impresa - Venezia 18.05.2012 Since 2010: Continous Improvement through „From System CIP to Point CIP“ 4 System CIP Workshops per year Duration 2 days Participants: PM (PT, PC), VSMgrs Department Managers, Group Leaders, Planners First line shop floor manager (Foremen) External Fresh Eye Content of the System CIP LIVE Workshop: Customer Requirements 30’ Plenum Business Requirements, current/target state 30’ VSMgrs “Go to Gemba”LIVE, VSM/Bubble Diagram 180’ 7 Workgroups Development VSD/Bubble Diagram 180’ 7 Workgroups Definition of projects including KPIs and Tree 120’ 7 Workgroups Roadmap 180’ 7 Workgroups Release of projects by PM (PT,PC), VSMgrs 90’ Plenum Leaders drive with Speed the Improvement Process Diesel Systems / Chassis Systems Control 17 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 18. Salone d‘ Impresa - Venezia 18.05.2012 Positive experience: A Production System is a change of mindset: If you decide to do it, no doubt JUST DO IT The Production System isn‘t a Sprint, it is a Marathon Leaders: I can lead it Involve the whole organization Start consequently with 6S No Production System without 6S Deployment and Training through the entire organization Diesel Systems / Chassis Systems Control 18 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 19. Salone d‘ Impresa - Venezia 18.05.2012 Support Processes: Lean Administration approach Diesel Systems / Chassis Systems Control 19 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 20. Salone d‘ Impresa - Venezia 18.05.2012 BarP Lean Administration – VS visualization: Flusso di informazioni VSM = modello “swimlanes” Diesel Systems / Chassis Systems Control 20 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 21. Salone d‘ Impresa - Venezia 18.05.2012 BarP Lean Administration: High maturity level CIP Redefined running • Improvement process approach • Point CIP at managed at VSDiA office 100% lowest level Process • Organization • Strategy installed • Competence (employees, planers) mapping • Vision level 4 for • higher level Roll-out • Training for Lean • WS • Training managers assures a role of mentor • Training for referents Lean • Redesign • Lean experts of several Administrati • All the main key on starts processes processes • Basic are (VSD) training for mapped managers (VSM) 2009 2010 2011 2012 2013 2014 Diesel Systems / Chassis Systems Control 21 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 22. Salone d‘ Impresa - Venezia 18.05.2012 Since 2012 – Redefined approach: Revised strategy and long term vision New department fully dedicated to Lean Administration Structured VSDiA projects to assure : Reasonable duration (4 to 8 months) Adequate and stable results Put the basis for Lean Administration success story Diesel Systems / Chassis Systems Control 22 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
- 23. Salone d‘ Impresa - Venezia 18.05.2012 BarP Lean Administration: High maturity level CIP Redefined running • Improvement process approach • Point CIP at managed at VSDiA office 100% lowest level Process • Organization • Strategy installed • Competence (employees, planers) mapping • Training for • Vision level 4 for • higher level • WS managers assures a role Roll-out Lean referents • Training of mentor • Training for Lean • Redesign experts of several • Lean • All the main key Administrati processes processes on starts are (VSD) • Basic training for mapped managers (VSM) 2009 2010 2011 2012 2013 2014 Diesel Systems / Chassis Systems Control 23 BarP/ADM | 18/05/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.