Finbarr Dowling MAS2011 Presentation

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Finbarr Dowling Managing Director, Siemens Inverters

MAS Conference June 16th 2011 Old Trafford Innovate or Die

Finbarr Dowling Managing Director Siemens I DT MC I Congleton

Te d H o ff

A long history of innovation

Who we are

1971 1991 1996 1999

Siemens established at Congleton Designated electronics manufacturing factory GZ ASI 1S HQ A&D SD D Design, Manufacture & Technical CS

Total land area:21,000 m2 Building area (office + production ):12,000 m2 Employees: (510)

Congletons manufacturing technologies and products

Sinamics G120 Modular

Sinamics G120D

Sinamics G110

Micro Master Integrated

Surface Mount Technology

Through hole Technology

PCB Test Technology

Coating Technology

Mechanical Technology

Our CompetenciesElectronic production of Industrial products in the area of low complexity, high volume Variable Speed Drives & Ancillary equipment on a world class level in regards of excellent product quality, high productivity and highest logistic performance.

Develop robust, competitive product families for the global market with core competence for high IP rated products. Highly qualified engineering and qualification services for material, processes (incl. Design for Manufacture & Design for Test) and equipment. Design, programming, manufacturing and documentation of function test equipment for Inverters, Options and HMI. Professional project management supported by excellent PLM and NPI processes

Third tier Customer Support using the advantage of local production and R&D facilities.

Repair Centre offering NPI dynamic feedback and customer special investigations.

1971-2011 Manufacturing as a % of GDP - UK

Congleton sales 2002-11

Our Vision

Our Strategic Themes

The key is constant productivity through innovationIncreasing Effort / Complexity for Implementation


Six Sigma

Business Improvement Projects

LEAN Cell Design

LEAN In the Office

Continuous Improvement Process


Outputs from the Productivity FunnelBusiness Improvement ProjectsLEAN In the Office Continuous Improvement Process


Six Sigma

LEAN Cell Design


Good Example. Designed new improved cover with less labelling and improved PCB together with new software and keypad with significant quality improvements Savings 42000/Yr

Good Example. Skiipsare damaged upon power up if excess paste is applied during printing. 6 Sigma methods used to identify and reduce scrap.

Saving 11,335/Yr

Good Example. A third party supplier was used to customise our G110 drives for UK customer. By setting parameters inline we have eliminated the need for the third party. Saving 9,693/Yr

Good Example. VS2 LCD team on G110D production line have achieved reduction in floor space by 50% together with process improvements and WIP reduction Saving 81,944/Yr

Good Example. A Material Handling LIO team identified that a saving could be achieved when ordering batches of 10,000 pieces instead of 1000 piece.

Good Example. A CIP team identified that one operator can now operates two PCB test systems at the same time instead of one system each.

Saving 29,412/Yr

Saving 183,243/Yr

Good Example. An alarm to alert operators when pallet gets stuck at oven entrance, so that they can solve the problem rather than letting the pallets build up to a backlog situation.

Saving 12,107/Yr

YTD 161K Target 406K

YTD 8K Target 100K

YTD 0 Target


YTD 116K Target 170K

YTD 195K Target 150K

YTD 617K Target 475K

YTD 312K Target 400K

* (YTD = End April 2011 ), including all productivity measures VAM , CRI & Cost avoidance .

Excludes 430K roll over

The UK Skills squeeze and challenge H i her g E d u ca ti n o3 0 0 , 0 0 0 U K G ra d u a te s / ye a r o n l 1 0 , 0 0 0 y e n g i e e ri g ( C h i a p ro d u ce s 6 0 0 , 0 0 0 e n g i e e ri g n n n n n g ra d u a te s) 3 0 % E n g i e e ri g G ra d u a te s ta ke ca re e rs o u tsi e o f n n d e n g i e e ri g n n G ra d u a te s o fte n d o n t h a ve th e ri h t ski l g ls

I te rm e d i te n a

R e a lski l sh o rta g e a t te ch n i a n l ve l M a n u fa ctu ri g ls ci e . n w i ln e e d a t l a st a d d i o n a l5 8 7 , 0 0 0 n e w w o rke rs o ve r l e ti n e xt 1 0 ye a rs m a i l te ch n i a n s n y ci A p p re n ti a n d te ch n i a n ro u te se e n a s se co n d ce ci cl ss a l rn a ti to U n i rsi a te ve ve ty 4 0 % o f E n g i e e ri g w o rkfo rce a g e d > 4 5 n n Po o r p e rce p ti n o f e n g i e e ri g a n d m a n u fa ctu ri g o n n n To o fe w stu d e n t ta ki g S T E M su b j cts n e Lo w ski l a n d a sp i ti n s ls ra o N u m b e r o f 1 6 - 2 4 ye a r o l s w i ld ro p b y 8 % i n e xt d l n 1 0 ye a rs

S ch o o l E d u ca ti n o

Associations CBI / EEF/Royal academy of Eng.

Government & Ministerial Advisory Groups

N a ti n a l o engagem ent

Siemens approach to address the squeezeH i her g E d u ca ti n oEducational STEMNET / Engineering UKE3 & Power Academy

Key Pro g ra m m e s

Lincoln UniversityIndividual Universities Diplomas/Apprenticeships

Professional bodies IET/IMechE

Sector Skills Councils - Semta

Manufacturing Insight/Futures

I te rm e d i t n a e

PM@Siemens Academy Commercial Academy Wind Power Maintenance Diversity eg WISE Programmes; Big Bang etc.

S ch o o l E d u ca ti n o

Schools & Ambassador pr. LEAs and local agencies

Work placements

Key ProgrammesAttraction and Recruitment


1 Workstream 1 Education / SchoolsPrimary Secondary & 6th Form Secondary & 6th Form (Colleges)

Workstream 2 GraduatesUndergraduate sponsorship Graduate Recruitment





Encourage & Engage

Workstream 3 ApprenticesApprenticeship


Make ItWhat Who How ResultMake It helps young people discover what manufacturing means and how it could lead to a rewarding and exciting career in the future Partnership with The Manufacturing Institute 6 Siemens managers acting as Dragons Apprentices and graduates help the children on the day as consultants In our first Make It day 120 children from 10 local schools took part They are set challenges to 3 different problems and choose 1 to work on We provide the facilities and hospitability 98% of children felt it gave them a better understanding of the careers available in Manufacturing. In addition at the outset 52% said they would consider a career in Manufacturing at the end 82% said they would.


Sustainable Employee Engagement

NGO Customer Others

With Partner Integrated in local business strategy

Uses Siemens technology Qualitative KPIs Quantitative KPIs

Girls can do it too!WhatSiemens Motion Control in Congleton are encouraging girls and young women into engineering careers. Primary and secondary schools with Siemens (plus other businesses) are working together in establishing a long term transferable model for the learning and skills sector.



Events aim to increase the number of girls taking up engineering diplomas, apprenticeships and careers. Siemens has developed a program of factory tours, talks, events and competitions.


Sustainable Employee Engagement

NGO Customer Others

With Partner Integrated in local business strategy

Uses Siemens technology Qualitative KPIs Quantitative KPIs

GreenpowerWhat Who How ResultGreenpower is working with schools across theUK to encourage students to build andrace their cars at motor racing circuits. Each race lasts for 4 hours so reliability, energy efficiency and innovation are key. 50 Siemens volunteers support the Greenpower events acting as stewards and marshals Apprentices and graduates help schools with the building of cars Around 600 schools and10,000 students across theUK are taking part Targeting schools close to Siemens sites to increase participation Provide PLM software to all the schools participating Greenpower is monitoring the take up and success of students taking physics, maths and sciences to judge how effective the programme is improving student performance


Sustainable Employee Engagement

NGO Customer Others

With Partner Integrated in local business strategy

Uses Siemens technology Qualitative KPIs Quantitative KPIs

Big BangWhat Who HowThe Big Bang is the UKs biggest single celebration of science and engineering for young people. Attracting over 23,000 students over three days from schools around the UK. 20 Siemens graduates, apprentices and other employees volunteered to man the event for three days Siemens 4d ultrasound scanner on a phantom baby. Build a wind turbine model in action Practical e-car building with Greenpower Over 58% of secondary pupils indicated that they were more likely to choose a STEM qualification. Siemens booth was voted in the top 10 attractions



Sustainable Employee Engagement

NGO Customer Others

With Partner Integrated in local business strategy

Uses Siemens technology Qualitative KPIs Quantitative KPIs

The Urban Sustainablility Centre - London

Apprentices - Siemens plc works with national partners

Siemens Energy example Siemens took apprenticeship training in-house in 2008 To guarantee the quality of training provision to meet Siemens plc requ