MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Introduction

to MPS

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

By the end of the class, you will be able to describe:

What are the learning objectives for our class?

• the purpose of a Production System

• the history of Production Systems

• how the Mercedes-Benz Production System (MPS) was developed

• how the Mercedes-Benz Production System is structured

You also will start learning to see how key elements of the Mercedes-

Benz Production System are implemented at MBUSI.

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

What is a production system?

A

production

system

Description of

procedures, methods

and rules in our plant

Base for T/M

training and

development

Base for our daily

operations

Instruction for Team Members

and Management how to handle

tasks and responsibilities

Creates standards

which we will improve

continuously

Base for continuous

improvement of our

product and our

production procedures

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

History of the Production Systems

First automated production

stop due to quality problems

by Sakichi Toyoda

Introduction of the station sheet

by Taiichi Ohno

Kiichiro Toyoda:

- Tool change over time reduction

- Just-in-time-Philosophy

Further Development of the PS

- Elements:

Quality, Visual Management,

Standardization, Stability,

Elimination of waste

Opel-Eisenach-PS

- First PS in Europe

Various car manufacturers/

suppliers

e. g. Mercedes-Benz, Chrysler,

Ford, Skoda, Audi ...

Development of Toyota-PS- Pull-System, KANBAN-System as additional

measures

Nummi-joint-venture USA

(General Motors and Toyota)

- Lean Management principles

in western part of the world

1990

since 1995

1982

1956

19401902

1945

1960J

A

P

A

N

E

U

R

O

P

E

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Development of the DaimlerChrysler-Production System

etc.

Qualität

Fabrik-, Anlagen-

and Prozeßplanung

(FAP)

Visualisierung

Führung

Standardisierte

Prozesse and

Methoden

(SPM)

Arbeitspolitik

(Gruppenarbeit,

KVP, REZEI)

Qualifizierung

Produktions-

mittel- and Anlagen-

betreuung

Sicherheit

Sauberkeit

Ordnung

(SSO)

Material-

versorgung

Umwelt- and

Arbeitsschutz

(AUS)

UPI

5A

KVPDiag-nose

Ver-schwen-

dung

Pro-blem-lösung

Visu-elles

Mgmt.

Stan-dardi-sierg.

Vision,Goalauf-lösung

QM

Log,

JIT

Werkzeugsysteme

Technik

Werkzeugsysteme

Organisation

Werkzeugsystem

Mitarbeiterförderung

Grandelemente

WF+

TA

Aut

+LCA

F+E

LE

S+V

Werkzeuge

Sic

herh

eit

/U

mw

elt

sch

utz

Qu

ali

tät

hat

Vorran

gE

rh

alt

un

g +

Verb

ess

eru

ng

In D

ate

nsp

rech

en

Prozess

-orie

nti

eru

ng

Sch

lüss

el

/S

ch

loß

Kein

e S

ch

uld

-zu

weis

un

gP

rob

lem

e s

ind

Ch

an

cen

Sta

bile P

rozesse /

Pro

du

kte

an

d p

räv

en

tiv

es

Qu

alitä

tsm

an

ag

em

en

t

Kla

rheit

vo

n R

ollen

Fü

hru

ng

Bete

ilig

un

g a

nd

En

twic

klu

ng

vo

n M

itarb

eit

ern

Gru

pp

en

arb

eit

sstr

uk

ture

n

Arb

eit

ssic

herh

eit

an

d U

mw

elt

be

wu

ssts

ein

Sta

nd

ard

isie

rte M

eth

od

en

an

d P

rozesse

Vis

uelles M

an

ag

em

en

t/5

A

Sch

nelle P

rob

lem

erk

en

nu

ng

an

d F

eh

lerb

ese

itig

un

g

Kan

den

ori

en

tieru

ng

(in

tern

an

d e

xte

rn)

Pro

du

kti

on

sg

lätt

un

g

Pu

ll-P

rod

ukti

on

Fließ

fert

igu

ng

Taktf

ert

igu

ng

Beseit

igu

ng

vo

n V

ers

ch

wen

du

ng

Just in TimeKontinuierliche

Verbesserung

Qualität

and robuste

Prozesse /

ProdukteStandardi-

sierung

Arbeitsstrukturen and

Gruppenarbeit

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Levels of the Production System:

Human InfrastructureStandardi-

zation

Continuous

ImprovementJust in Time

Quality and stable

processes and

products

Pro

du

cti

on

Sm

oo

thin

g

Pu

ll P

rod

uc

tio

n

Co

nti

nu

ou

s F

low

Pro

ce

ssin

g

Cu

sto

me

r D

em

an

d R

ate

Vis

ua

l M

an

ag

em

en

t

Le

ad

ers

hip

Ro

le C

lari

ty

Em

plo

ye

e D

eve

lop

me

nt

+

Invo

lve

me

nt

Wo

rk G

rou

p O

rga

niz

ati

on

al

Str

uctu

re

Sa

fety

an

d E

nvir

on

me

nta

l

Aw

are

ne

ss

Sta

nd

ard

ize

d M

eth

od

an

d

Pro

ce

du

res

Sta

ble

Pro

ces

se

s/P

rod

uc

ts a

nd

Pre

ve

nti

ve

Qu

ali

ty M

an

ag

em

en

t

Qu

ick

Is

su

e D

ete

cti

on

&C

orr

ec

tio

n

Cu

sto

me

r F

oc

us

(in

tern

al

+ e

xte

rna

l)

Wa

ste

Eli

min

ati

on

MPS methods and tools

Safety, Quality, Delivery, Cost, Morale (S, Q, D, C, M)

Res

ult

sM

eth

od

sP

rod

ucti

on

pri

nc

iple

Su

bsys

tem

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

What are our objectives with MPS, now and in the future?

We produce our M-class through reliable processes and clear responsibilities without overloading our Team Members

Our production procedures are lean with no wasted resources.

We produce the highest quality at competitive costs by working as a team

We constantly improve and keep learning.

... everybody does what he/she wants

Without MPS ...

... we have a commonunderstanding

With MPS ...

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Our vision:

“We work as a Team to satisfy and delight our customers

100 % with every Mercedes we build.”

Let us clarify, who is our customer:

As a Team Member our internal customer is always

the next process = the next Team Member

External Customer

1. MBUSA

2. Dealers

3. And finally the owner of our M-class.

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Human Infrastructure

1.1.8 Standardized Communication Channels

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Human Infrastructure1.3.1. On the Job Training

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Standardization

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Standardization

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Quality Focus and Robust Processes and Products

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Just in time

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Continuous Improvement

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Example: Continuous Improvement

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

MPS is how we operate our business, with every

car, every process, every transaction

EVERY DAY!

MPS is the responsibility of all Team Members!!!

MPS Introduction

Mercedes-Benz Produktionssystem MBUSI

Mines - May 2004

Are you ready?