Francis Hiew

IIEA14 July 2021

Experience Sharing Session onOperational Excellence in Aerospace Manufacturing Industry

MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN

MRO

FH - Introduction

1997-1999

Pacific Aviation Composites LLCBend, Oregon, USAAVP – Operations

Lancair Columbia 300

• 4-Seater all composites GA – F

• Design, development, certification and production

1999-2008

Composites Technology Research Malaysia Sdn. Bhd, Malaysia (CTRM)General Manager , COO

• Advance Composites Aero-Structures Mfg for Airbus & Boeing

• Aviation- Eagle Aircraft 150B• Aerospace Design Center • UAV & Systems Integration

(Defense)• Advance Composites –

Automotive, Marine

2008 -2016

Spirit AeroSystems Malaysia Managing Director

• Aero-Structure Assembly• Aero-Structure Design• A320, A350, 737,787• Regional Supply Chain

Development

• Malaysia Aerospace Industry Association –Deputy President (2016-2017) MAIA

2017 - Present

Francis Hiew Consulting (Malaysia)

• Spirit AeroSystems Malaysia –Director (2018), Consultant (2019)

• MAIA – Advisor• Aerospace tooling capability

development• Training & Advisory

• Strategy • Leadership• Skill and Capability• Lean & Continuous

improvement

MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN

MRO

Spirit AeroSystems Malaysia Sdn Bhd

• Established in 2008, Subang Airport. Selangor Malaysia• Wholly owned subsidiary of Spirit AeroSystems Inc, Wichita, USA. • Core Capabilities –

• Metallic and Composites Aero-Structure Assembly• Product Design• Supply chain development and management

Products:A320 – Flap Track Fairing, Spoilers, Over-wing Panels, etc.A350 – Root End Fixed Fairing , Leading Edge Panel Assembly787 – Fixed Leading Edge737 – Doors, Fuselage sub-assemblies,

MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN

MRO

Spirit AeroSystems Malaysia Sdn Bhd

Version 2SPIRIT PROPRIETARY

Spirit Malaysia Roadmaps

Spirit Malaysia Roadmaps

LEAN Roadmap

Operations Roadmap

Growth Roadmap

Supply Chain Roadmap

Talent Management Roadmap

Technical Roadmap

Recognition/Certification Roadmap

Preferred Future State

(Operational Excellence)

• Reduction in Total Unit Cost.• Improved Product Cycle Time.• Reduction in Cost of Product Quality• Improved Inventory Management

The existing Spirit Malaysia roadmaps are steering the organization towards Operational Excellence

4Spirit MalaysiaProprietary Information - Spirit AeroSystems Malaysia Sdn Bhd

AIMS 2009AIMS 2010AIMS 2011AIMS 2012AIMS 2013AIMS 2014AIMS 2015

Vision

Mission

5 Year Preferred Future State

Tech

nica

l R

oadm

ap

Lean

R

oadm

ap

Supp

ly C

hain

R

oadm

ap

Tale

nt

Man

agem

ent

Roa

dmap

Gro

wth

R

oadm

ap

Rec

ogni

tion/

C

ertif

icat

ion

Roa

dmap

Core Values

Getting there ...

Version 2SPIRIT PROPRIETARY

Journey Towards Operational Excellence through a Sustainable Review Process

RESOURCES CAPABILITIESKNOWLEDGE

Setting of goals / targets

Defining the current status of the

various sites (Gap Analysis)

Defining strategies / roadmaps

Developing a sustainable review process to manage

performance

Milestones and targets assessment/alignment conducted on an annualbasis (Head of Sites)

• Operational Excellence Conference conducted on a quarterly /half-yearly basis to report progress on CI activities• Annual site assessment for LEAN / CI

Strategies / Roadmaps to be reviewed on an annualbasis to align short term milestones to goals/target

Formal Monthly Review/Tracking on CI activities at various sites through Internal Management Meetings and Contract Reviews

Vision Rolling 5-YearRoadmap

Annual BudgetAction PlanCompany –KPIPerformance Bonus

Department - KPIs & BudgetWork Center - KPIs & BudgetKPIs Tracking

Daily-Weekly – Monthly- Quarterly

Employees of all levels and all departments share and own the company’s Vision, Strategies, Action Plans and Budget

MRO

Operational Excellence Journey Composites Technology Research MalaysiaSpirit AeroSystems Malaysia

Constraint Management

5S + Safety

Process ControlVisual Management System

Defects Prevention-Poka-Yoke-Hot Spot Visual Training

Self Manage Team

Kaizen – Continuous Improvement

Standard works

Skill & Product Training

Product Training Manual

One Piece Flow

Andon Light – Call for Action

Strategically placed inventory

Lean Awareness Training

Root Cause Corrective Action

Lean Roadmap

Value Stream Mapping

Visual Learning –Good part / Bad part

Operational Excellence Roadmap

Autoclave – SMED process

KPI Pyramid

Line BalancingLesson Learnt

Lean Maturity

Smart Tooling (Jigs & Fixtures)

Focus Improvement – Rapid Improvement Workshop

Waste elimination

TPM

Business Continuity Plan

MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN

MRO

Spirit AeroSystems Malaysia Sdn Bhd – Innovations and Achievements

Roadmap = Action Pan = Budget• ICE – Slush – Water• 18 months – 3 Year – 5 Year18 Months – ICE = Budget 3-Year = Slush 5-year = Water

- Pledge to change - Change Leadership- Change agent

training- Lean – 5S training- Set KPI- Data collection

system- Strengthen current

customers base- Path to earn the right

to grow

- Set technology path

- Build and protect business differentiators

- Self Managed Teams

- Target for new customers

- Target for new industries

- Ready for growth

- Set Path as market leader in??

- Brand recognition- Industry 4.0 ready

Jigs & Fixtures- Best value J&F in

the region- Ready for export

to USA & Europe

Regional Tooling Capability Development- Started 2016- All Assembly J&F sourced locally in

the region by 2019- Smart Tooling – IR4.0 ready

2Spirit Proprietary

Lean Road Map

Implementation

Monitoring

ReviewsLean Maturity Assessment

Overview of Continuous Improvement Program

• TRAINING & AWARENESS• EXECUTION

ü Monthly 5S competitionü Improvement and Focus

projects registration

VALIDATIONü Financial numberü Effectiveness ü Sustainability Customers comments:

✓Best in Class✓Benchmark for Operational Excellence✓Excellence training and capability development program

Developed Regional Supply Chain• Capability Insertion• Certification• Strengthen Regional Supply Chain

Eco System

MAIA MEMBERS WITHIN THE AEROSPACE SUPPLY CHAIN

MRO

Turning Vision and Strategy Into Reality

Operational Excellence RoadmapLean RoadmapTalent Management RoadmapSupply Chain RoadmapGrowth RoadmapTechnology RoadmapRecognition & Certification Roadmap

Turning Vision and Strategy into Reality