Emerson Climate Technologies manufactures heating, ventilation, air conditioning and refrigeration solutions across 3 product families at its largest European manufacturing location in Welkenraedt, Belgium. The complex processes involve machining and assembly across multiple lines. All processes are mapped in Adonis for innovation, customer focus, productivity and quality. Short term "daily changes" like control plan updates number 400 per year while long term "major changes" like new product introductions require integrating changes across models. Managing the complexity involves synchronizing updates to multiple process models reflecting both short term changes and new product assessments.

1. Managing Complexity ofManaging Complexity of
ProcessProcess ChangesChanges
By Christine SchmetzBy Christine Schmetz
Quality System Services ManagerQuality System Services Manager

2. 1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 2
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…

3. 11--1 About Emerson1 About Emerson
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 3
A diversified technology company with
US$ 20.9B of sales worldwide in FY 09.

4. 11--1 About Emerson1 About Emerson
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 4
129,000 employees
250 manufacturing locations worldwide –
165 located outside the United States.

5. 1-1 About Emerson Structure
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55
Europe USA Asia
Process
Management
Appliances
& Tools
Industrial
Automation
Network
Power
5 Financial
Segments
of Emerson

6. • Supermarkets
• Restaurants
• Pharmaceutical industry
• Air driers
• Milk cooling
• Industrial process
cooling
•Chillers
•Rooftop systems
•Commercial and Light
Commercial Heat Pumps
•Self-contained systems
•Water coolers
11--1 Emerson Climate Technologies1 Emerson Climate Technologies -- ProductsProducts & Markets& Markets11--1 Emerson Climate Technologies1 Emerson Climate Technologies -- ProductsProducts & Markets& Markets
REFRIGERATIONREFRIGERATION
COMMERCIAL
COMFORT
COMMERCIAL
COMFORT
•Chillers
•Rooftop systems
•Commercial and Light
Commercial Heat Pumps
•Self-contained systems
•Water coolers
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Air Conditioning and Heat
Pumps for residential
applications
• Trailers and commercial
distribution trucks
• Trains and busses
• Sea containers
RESIDENTIAL
COMFORT
RESIDENTIAL
COMFORT
TRANSPORTATIONTRANSPORTATION
Heating, Ventilation, Air Conditioning and Refrigeration solutions
for residential, industrial and commercial applications.
•Air Conditioning and
Heat Pumps for
residential applications
• Trailers and commercial
distribution trucks
• Trains and busses
• Sea containers

7. 11--1 Emerson1 Emerson Climate Technologies Products ManufacturingClimate Technologies Products Manufacturing11--1 Emerson1 Emerson Climate Technologies Products ManufacturingClimate Technologies Products Manufacturing
Welkenraedt, Belgium
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NORTH AMERICA:
Brantford, Ontario
(Canada)
Sidney, Ohio (4)
Hartselle, Alabama
Natchitoches, Louisiana
Ava, Missouri
Lebanon, Missouri
Rushville, Indiana
Reynosa, Mexico
Guadalajara, Mexico
EUROPE:
Cookstown, Northern Ireland
Welkenraedt, Belgium
Mikulov, Czech Republic
Kolín, Czech Republic (Alco)
Pieve d´Alpago, Italy (Dixell)
ASIA:
Suzhou, China
Shenyang, China
Karad, India
Atit, India
Rayong, Thailand
Dubai, UAE

8. 11--1 About our1 About our ManufacturingManufacturing LocationLocation in Belgium.in Belgium.11--1 About our1 About our ManufacturingManufacturing LocationLocation in Belgium.in Belgium.
Biggest Manufacturing
location in Europe
+/- 500 Employees
Max. capacity :
250.000 compressors
Machining and Assembly
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Machining and Assembly
Processes.

9. 1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 9
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…

10. 11--2 About2 About our Productsour Products11--2 About2 About our Productsour Products
3 Product Families
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SUMMIT
7.5-15Hp
SPECTER
7.5-15Hp
LCS
20-40Hp

11. 11--2 About2 About ourour Machining & Assembly ProcessesMachining & Assembly Processes11--2 About2 About ourour Machining & Assembly ProcessesMachining & Assembly Processes
1 Machining area – 2 Zones (Turning & Milling)
Turning
Milling
2 Main Assembly Lines - 3 Product Families–
Merging into 1 for the Final Process
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LCS /
SPECT
ER
LS
H
DS
Summit
Ass.
Specter /
LCS Ass. Final Test
Pack.
Painting

12. 1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 12
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…

13. 11--3 Adonis3 Adonis asas ourour centralcentral ProcessProcess ModellingModelling PlatformPlatform
40 Main Processes
65 Sub Processes
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PRODUCTION PROCESS FLOWADMINISTRATIVE PROCESSES
3 Assembly Lines
Machining Area

14. 11--3 Mapping Manufacturing Processes3 Mapping Manufacturing Processes –– Why ?Why ?11--3 Mapping Manufacturing Processes3 Mapping Manufacturing Processes –– Why ?Why ?
Innovation :
Quick Respond to Market Needs and Trends
=> Introduction of new Products on existing lines
Customer Orientation :
Professional way to communicate with customers / auditors about
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Professional way to communicate with customers / auditors about
control plan, process flow, changes made on process….
Productivity :
Continuous Rebalancing of the line to increase Productivity
(automation of operation, new equipment, move operation…).

15. 11--3 Mapping Manufacturing Processes3 Mapping Manufacturing Processes –– Why ?Why ?11--3 Mapping Manufacturing Processes3 Mapping Manufacturing Processes –– Why ?Why ?
Quality :
Ensure Flexibility and Continuous Improvement of the Control Plan :
1- Increase / Decrease control frequency :
- Justified by problems encountered,
- By equipment capability,
- FMEA risk analysis
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- FMEA risk analysis
2- Add / Suppress Control
3- Change Ownership of Controls
Demand Driven :
Ensure efficient training of new operators (peak season)
Ensure flexibility of operators on the line (ability to work on various
workstations)

16. 11--33 ManufacturingManufacturing ProcessesProcesses -- SpecificitiesSpecificities
- Many Product variations on same Assembly Line.
-1 Model per Manufacturing Process (including various products)
LCS
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17. 11--33 ManufacturingManufacturing ProcessesProcesses -- SpecificitiesSpecificities
Work-, Control-, Checking-, Mastering Operations
Work Op.
Control Op.
Unique ID N°
Color Codes
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Control Op.
Checking Op.
Mastering Op.

18. 11--3 Link3 Link between Operation and Controlsbetween Operation and Controls11--3 Link3 Link between Operation and Controlsbetween Operation and Controls
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Automatic Link to the
related Control Operations

19. 11--3 Key Figures3 Key Figures
3 Assembly Lines Machining Area
84 Workstations 23 Workstations
230 Work Operations 78 Work Operations - 232 Sub Op.
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230 Work Operations 78 Work Operations - 232 Sub Op.
214 Control Operations 587 Control Operations
65 Checking Operations 52 Checking Operations
125 Equipements 60 Equipements
600 Documents 350 Documents

20. 11--3 Elements linked to an Operation3 Elements linked to an Operation11--3 Elements linked to an Operation3 Elements linked to an Operation
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21. 1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
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2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Outlook: Issues to be solved…

22. 2. Different Types of Changes2. Different Types of Changes2. Different Types of Changes2. Different Types of Changes
Keep processes up too date
« Daily changes » - Short Term – Versions / Status
Current model is being updated to reflect short-term changes
Versus
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Integrate new product, new cell…
« Major change » - Long Term - Variants
Daily Changes must be integrated on a regular basis on the model +
the model serves as basis for the implementation of major mid- or long term
changes.

23. 22--1 „Daily Changes“1 „Daily Changes“ –– Key FiguresKey Figures22--1 „Daily Changes“1 „Daily Changes“ –– Key FiguresKey Figures
Ca. 400 Changes / year
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Ca. 250 Changes / year

24. 22--1 „Daily Changes“1 „Daily Changes“ –– Key DriversKey Drivers22--1 „Daily Changes“1 „Daily Changes“ –– Key DriversKey Drivers
Control plan (control frequency, add/suppress….)
Operations (line rebalancing => reallocate operations & operation
content)
Suppress / Add machining sub operations
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Introduction of new tooling, equipement,…
…
=> Communication, Reactivity, Integration and Traceability

25. 22--1 „Daily Changes“1 „Daily Changes“ -- Get InformationGet Information22--1 „Daily Changes“1 „Daily Changes“ -- Get InformationGet Information
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26. 22--1 „Daily Changes“1 „Daily Changes“ -- Prepare Change ImplementationPrepare Change Implementation22--1 „Daily Changes“1 „Daily Changes“ -- Prepare Change ImplementationPrepare Change Implementation
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-Increment Version of current model - « Save as » in the DRAFT Folder (move ref.)-
-Change Status in « DRAFT »

27. 22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes
-Identify Impact of Changes
-Search
-Object references
-Related Controls
-….
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-….

28. 22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes
- Implement Changes on process flow and related elements :
-Documentation
-SOEs
-Equipment => EQM software
-Control Plan
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29. 22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes22--1 „Daily Changes“1 „Daily Changes“ -- Implement ChangesImplement Changes
- Track changes in History
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30. 22--1 „Daily Changes“1 „Daily Changes“ -- ApproveApprove22--1 „Daily Changes“1 „Daily Changes“ -- ApproveApprove
- Publish DRAFT Model in HTML
-- Send approval mail (votting buttons) and get « Approve » or
« Comments »
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31. 22--1 „Daily Changes“1 „Daily Changes“ -- PublishPublish22--1 „Daily Changes“1 „Daily Changes“ -- PublishPublish
- Change status of current model in « Archived »
- Drag current model in folder ARCHIVED – ADL export on server
- Change status of draft model in « Released »
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- Change status of draft model in « Released »
- Drag in folder RELEASED
- Inform users per e-mail of new version (+ change history)

32. 22--2 Major Changes2 Major Changes22--2 Major Changes2 Major Changes
Introduction of a new product on existing Assembly Line (ex. REF
Summit)
⇒Existing process as a basis :
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⇒ to assess required investments and changes
⇒ to develop control plan
⇒ to establish or review documentation…

33. 22--2 Major Changes2 Major Changes –– Current situationCurrent situation22--2 Major Changes2 Major Changes –– Current situationCurrent situation
Changes related to the new « product » are :
- Integrated in the current model – Red Agregation.
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34. 22--2 Major Changes2 Major Changes –– Current situationCurrent situation22--2 Major Changes2 Major Changes –– Current situationCurrent situation
New product is added in the product model.
-New product is added in the new / existing operations.
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35. 22--2 Major Changes2 Major Changes –– Current situationCurrent situation22--2 Major Changes2 Major Changes –– Current situationCurrent situation
By clicking on the new
Product in the product model,
Point at operations referring
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Point at operations referring
To this new product.

36. 22--2 Major Changes2 Major Changes –– Current situationCurrent situation22--2 Major Changes2 Major Changes –– Current situationCurrent situation
- Red Agregations will dissapear when new product is released.
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37. 1- Introduction
1.1 Emerson – Emerson Climate Technologies
1.2 Products & Manufacturing Processes
1.3 Mapping Manufacturing Processes
Table of ContentsTable of ContentsTable of ContentsTable of Contents
BOC Strategic Meeting Sept 10 – Managing Complexity of Process Changes Page 37
2- Complexity of Process Changes
2.1 Short Term Changes – Versions / Status
2.2 Long Term Changes – Variants / Target State
3- Challenge: Issues to be solved…

38. 3. Challenges3. Challenges3. Challenges3. Challenges
2 (or more) models being updated in parallel :
-To reflect short term changes.
-To assess / prepare new product implementation.
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-SYNCHRONIZATION….

39. Thank You For Your Attention !Thank You For Your Attention !
Christine.Schmetz@emerson.com
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Christine.Schmetz@emerson.com