Implementation of lean in Vestas Nacelles, 11th May, Lean Excellence seminar of Advance Business Network (www.advanceschool.org), F. Velluto, E. Nicoletti

1. 11
Lean In Vestas Nacelles Italy
The Lean Manufacturing Journey

2. Francesco Velluto
- VP Divisione Vestas Nacelles A/S
- AD Vestas Nacelles Italia – Taranto
- 49 anni, sposato, una figlia di 12 anni
- nel settore eolico dal 1990
- in Vestas dal 1998
2
E siamo più di 20.000 dipendenti che credono nel vento

3. 3
Elisa Nicoletti
- PEX Manager
- 34 anni
- in Vestas dal 2008

4. 44
Content
1.Vestas: introduction to the company and its business
2.Vestas in Taranto
3.Vestas Journey through Lean Manufacturing

5. 55
Reaching our vision
Wind is…
Reducing green house
gas emissions and
climate change
Creating
jobs and
investment
Building energy
security
Reducing
dependence on
fossil fuels
CO2
Introduction to the company
and its business

6. 66
We have installed close to 49,000 turbines in 73 countries
worldwide spanning six continents49,000
We monitor almost 25,000 turbines, or 43,000 MW, day and night
and the data is used for efficient service planning and pre-emptive
maintenance
25,000
We employ around 18,000 people worldwide from 85
nationalities and have more than 30 years of experience with
wind energy
18,000
Vestas in brief
*Source: BTM Consult, 2012

7. 77
We are a truly global organisation

8. 88
55 GW amounts to 49,000 turbines, which generate enough clean energy to power over 19
million European households.
Vestas has installed just over one out of every five wind turbine MWs installed around the globe
* *
Vestas has installed 55 GW of wind energy
65% more installed capacity than our closest competitor*
*Source: BTM Consult, 2012. * * Source 238 GW (at the end of 2011), according to the Global Wind Energy Council (GWEC).

9. 99
Our vision
Wind is…
Reducing green house
gas emissions and
climate change
On par with oil
and gas
Building energy
security
Reducing
dependence on
fossil fuels
CO2
Bringing wind on par with oil and gas
Our aspiration, stated through our vision, is a society where at least 20% of the global
electricity supply is provided by wind.

10. Industry leading track record in turbine development
10
Vestas’ track record of turbine evolution over 30 years is unmatched in the wind industry
8.000

11. … backed by performance guarantees
Superior service and certainty through:
the right PEOPLE, supported by
the right INTELLIGENCE, using
the right OPERATIONS AND MAINTENANCE plan,
the right INFRASTRUCTURE, maintaining
a strong PARTNERSHIP
Operation & Optimisation: Active Output Management
Our commitment to you
11

12. 1212
Safety comes first at Vestas
33% annual reduction of industrial injuries at
Vestas since 2006.
In 2012 there was record low 2.8 injuries per one
million working hours
In 2015, the target is 0.5injuries per one million
working hours
Incidence of industrial injuries
(per 1 million working hours)
25,3
20,8
15,6
8,1
5,0
3,2 2,8
2006 2007 2008 2009 2010 2011 2012

13. 1313
Servicing throughout the wind project value chain
Vestas is dedicated to working in partnership with customers to deliver the lowest cost
of energy and maximum return on investment in wind energy.
Financing. Siting. Grid requirements.
Local policy and regulations.
Customers need to consider a wide
range of crucial factors when they
invest in a wind power plant. And not
just at the planning stage, but for the
whole lifecycle of the project.
Project planning
When customers choose a wind power
supplier, they need a business partner
with a track record of innovation,
commitment and success of delivering
wind power plants. A partner like
Vestas.
Procurement and construction Operation and optimisation
Building a wind power plant is
one thing. Operating it at
optimum efficiency is another.
Whether it is managing and
maintaining the turbines,
training customers to operate
them..
Edit ”purple” bar to
cover full cycle
Vestas in Taranto

14. 1414
Vestas Nacelles Italia
Vestas Blades Italia Vestas Italia

15. 1515
Servicing throughout the wind project value chain
Vestas is dedicated to working in partnership with customers to deliver the lowest cost
of energy and maximum return on investment in wind energy.
Financing. Siting. Grid requirements.
Local policy and regulations.
Customers need to consider a wide
range of crucial factors when they
invest in a wind power plant. And not
just at the planning stage, but for the
whole lifecycle of the project.
Project planning
When customers choose a wind power
supplier, they need a business partner
with a track record of innovation,
commitment and success of delivering
wind power plants. A partner like
Vestas.
Procurement and construction Operation and optimisation
Building a wind power plant is
one thing. Operating it at
optimum efficiency is another.
Whether it is managing and
maintaining the turbines,
training customers to operate
them..
Edit ”purple” bar to
cover full cycle
«Vestas journey through
Lean Manufacturing»
 La trasformazione Lean in Vestas
 Le criticità e le soluzioni
 I benefici per gli stakeholder
 Lessons Learned

16. Introduction of new tools, systems, organizations in
order to improve the company’s competitive position
in the market
1. Product Innovation
New Products (Technology R&D)
2. Process Innovation
Assemble at lower costs
Lean
Manufacturing

17. Principio della Riduzione dei Costi: PROFITTO = PREZZO DI VENDITA - COSTO
Approccio
Lean
Approccio
Tradizionale
Profit
Profit
Profit
Costo
di
Prod
Costo
di
Prod
Costo
di
ProdPrezzo
di
Vendita
Prezzo
di
Vendita
VENDITE
Profit Profit
Profit
Costo
di
Prod
Costo
di
Prod
Costo
di
Prod
Prezzo
di
Vendita
Principio del Valore Aggiunto: PREZZO DI VENDITA = COSTO + PROFITTO
Spreco
VENDITE
Prezzo
di
Vendita
Cosa vuol dire “Eliminare gli Sprechi”
17

18. STABILITY
J
I
T
J
I
D
O
K
A
Continuous
Improvement
Culture
 Pull
 Takt
 Flow
 QbD
 Pokayoke  5S
 Visual Management
 Std. Work
The Lean Turbine

19. Taranto Plant - 2007
19
 Make to Stock
 Unbalanced Line
 High Lead Time
 High DoS
 Big Warehouse
 High WIP
 High FG stock
 High transportation
 High motion
Supplier Factory
Customer
FG
Forecast Demand

20. June 2007 - Taranto Factory – Assembly line Layout
20
Warehouse
Warehouse
Assembly Line
Assembly Line
Warehouse
Warehouse

21. “The Lean Journey in the Supply Chain”
21
Current State
Specify
Value
Identify
Value
Streams
Create
Flow
Leverage
Pull
Seek
Perfection
Lean
Supply Chain
5 Principles of Lean

22. Value Stream Mapping
• Preworkshop
• Current State
• Future State
Spread new culture

23. Inventory Hides Problems
Raw Material Finished Goods
Company
Line imbalance
Poor communication
Poor scheduling
Quality
Problems
Supplier
delivery
problems
Poor scheduling
Poor 5S
Long set up times

24. September 2008 - Taranto Factory – New Assembly Line Layout
24
Warehouse
Warehouse
Assembly Line
Assembly Line
Warehouse
Assembly Line
Warehouse

25. Lean in Vestas
25
Percorso Lean in Vestas Nacelles Italia
 Value Stream Mapping
 Taktime
 Da Make to Stock a Make to Order: PULL
 100% personale formato
 Bilanciamento della linea
 50% riduzione Lead Time
 91,5% Riduzione DoS
Supplier Factory
Customer
FG
FG
Forecast Demand

26. Continuous improvement: Striving for Perfection
Continuous improvement journey.
Produce exactly what the client wants, when they
want it, and at the lowest cost.

27. 27 | Vestas sustainability department
Thanks for your attention