1. Organizational Knowledge
Beyond Lean Approach
Carlos Eduardo DaSilva
Global Quality Manager
Freudenberg-NOK
www.mesa.org 2008 European Plant-to-Enterprise Conference
November 3-4, Prague, Czech Republic
2. The following Strategic Initiatives of
MESA International are associated with
this presentation:
Lean Manufacturing
Quality & Regulatory Compliance
Real-Time Enterprise
Carlos.DaSilva@fngp.com
3. Global Business with…
Global Supply
3,500 employees
$950 million • Global Key Account
Management
• Global Lead Center Structure
• Global Program
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Co
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m
a
ic
m
Management
un
un
m
i
ca
m
• Standardized Production
tio
Co
n
Technology
Communication • Cooperative R&D
• Employee Exchange
24,000 employees 7,000 employees
$3.5 billion $2.5 billion
Carlos.DaSilva@fngp.com
4. …World Class Processes
Best Practices – World Class Processes
Lean Systems Initiative: A Cultural Basis for Waste Elimination
Six Sigma: A Scientific Basis for Variation Reduction
Lean Thinking Case Study
Aggressive Six Sigma Program
Supply Chain & Outsourcing Initiatives
Product Development Best Practices Leader
Progressive Approach to APQP & Compliance
Carlos.DaSilva@fngp.com
11. Quality as Result of…
Data transformed becomes information.
Information transformed becomes intelligence.
Intelligence transformed becomes competitive advantage.
Carlos.DaSilva@fngp.com
12. …Human Excellence
Management
GROUP BEHAVIOR / ORGANIZACIONAL
TEAM BEHAVIOR
ACTION
INDIVIDUAL BEHAVIOR SKILLS
Assurance
ATTITUDE COMPETENCE
KNOWLEDGE
Carlos.DaSilva@fngp.com
15. Execution
“It transfers the maximum number of tasks and responsibilities
to those workers actually adding value to the car on the line, and it has
in place a system for detecting defects that quickly traces every problem,
…”
THE MACHINE THAT CHANGED THE WORLD
James P. Womack, Daniel T. Jones, and Daniel Roos
Carlos.DaSilva@fngp.com
17. TPS is not a Tool Box…
Carlos.DaSilva@fngp.com
18. TPS is Attitude…
Jidoka Just-in-Time
Highlighting/Visualization of Making only “what is
problems needed, when it is needed,
and in the amount needed
Quality must be built in during
the manufacturing process for Producing quality products
the Just-in-Time system to efficiently through the
function complete elimination of
waste, inconsistencies, and
unreasonable requirements
on the production line
Carlos.DaSilva@fngp.com
19. A normal day in the office…
Fast Response
“Luck”
or
Carlos.DaSilva@fngp.com
20. Real Time Process Control
Basic Model from 2002 case study at USA Company
IPC VISUAL
COMAKERSHIP
MANUFACTURING
KNOWLEDGE
SUPPLIER KNOWLEDGE FACTORY
BEHAVIOR
Database Database 5S
Reports
Just in Time
Reports Visual Aid
MRB CAR KanBan
Integration
KPI KPI Center
Carlos.DaSilva@fngp.com