Battery production
Some systems within material handling need to be redesigned in order to boost the productivity of production workers. The systems concerned have been in operation for so long that a retrofit is no longer possible.
The problem
In the new handling system, the work steps involved in handling material can be automated so that 25 to 50% of the personnel costs can be reduced in the respective area.
Challenge
It is very difficult for the line organisation to perform the specification of the system alongside daily business. The engineers involved identify the deficiencies in the specification phase at the latest during commissioning. This causes the commissioning of the system to be prolonged and the designated budget and project duration are exceeded.
Solution (Lean CTQ, Lean Kano model, PRINCE2 LOP):
In collaboration with the involved teams and system suppliers, the available specification of the system (e.g. magazine gripper, bagging station, laser cabin, clamping unit, welding fume extraction, system operation control, cycle time, technical availability) is converted into our standard Lean CTQ (critical to quality) table.
Each CTQ row corresponds to a technical requirement on the system. For each of these requirements, the test cases for acceptance are described including the target and tolerances for the results.
Using the Lean Kano model, the individual rows of the CTQ (requirements) can be prioritised from a customer viewpoint.
The CTQ table is coordinated with all of those involved (system supplier, Purchasing, Engineering, Production and Maintenance).
Result:
Points that are not completed at the time of our consultation are added to a PRINCE2-LOP according to the project management methodology (list of open points). The individual entries are scheduled in this LOP. The prioritisation results from the CTQ..
This methodology makes it possible to shorten the commissioning time by around 25%.
