growth : another source of waste · lean manufacturing is a systematic method for the elimination...

GROWTH : ANOTHER SOURCE OF WASTE

Marios Mitrosilis

Group Manufacturing Excellence ManagerKleemann Lifts

➢ Who is Kleemann?➢ How we became your 1st Choice in Lifts➢ Case study: Lean Manufacturing implementation

in the Electronics Factory

WHO IS KLEEMANN?

Manufacturing

We manufacture in Greece, China and Serbia

Prestigious Projects

Prestigious Projects

HOW WE BECAME YOUR 1ST CHOICE IN LIFTS

19831

9

9

0

1992

1995

1996

1998

1999

Growth: Main Factory Development

New Factories:• 1999: Doors Factory• 2001 : Electronics Factory• 2002 : Cabins Factory• 2004 : Logistics Center in

Athens• 2005 : Kleemann Liftovi

(Serbia)• 2011 : Kleemann China

2011 : Testing Tower (Greece)

• 61 meters high

• 3rd highest privately

owned testing tower

in Europe

• Developed lifts up to

6m/s

2019 : Testing Tower (China)

• 100 meters high

• To develop lifts >10m/s

Resulting Layout

Current Layout

CASE STUDY: LEAN MANUFACTURING IMPLEMENTATION IN THE ELECTRONICS FACTORY

Presenting work done by:

George Mitsas, Program manager "Lean Manufacturing Implementation“ at KLEEMANN

Chrysavgi Danaktsi, Lean Manufacturing Implementation at KLEEMANN

Lean manufacturing is a systematic method for the elimination of waste within a manufacturing system.

Lean also takes into account waste created through overburden and waste created through unevenness in work loads .

Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for.

Lean is centered on making obvious what adds value by reducing everything else.

Lean Manufacturing

Lean

Manufacturing

Goals : ➢ Controller assembly positions redesign➢ Precabling lean flow assembly line➢ Operating Panels lean flow assembly line➢ Design of a new Testing Area➢ Kanban implementation

Value Stream Mapping : Before

• Order Throughput: 9,2 days

• Production replanning has

heavy influence in

productivity

• Need of space for storing

semifinished parts

• Many transfers of parts to

different positions

Value Stream Mapping : After

• Order Throughput: 1,5 days

• Faster production planning

absorbs fluctuation in

demand

• 33,61% less space required

• Less transfers of

semifinished parts

Layout

AfterBefore

Before After % Improvement

Production [m2] 416 400 3,85%

Materials [m2] 698 369 47,13%

Semifinished Parts [m2] 112 45 59,82%

Total 1226 814 33,61%

Results

Results

• Order Throughput: from 9,2 to 1,5 days. (83,70% improvement)

• Fluctuation in demand is not transferred to production

• 33,61% less space required

• Less stock thanks to Kanban

• Less paperwork

• Simple visual inspection of production area

• Improved quality

• Improved productivity

• Continuous Improvement Culture

THANK YOU!