Carl Milbourne Head of Operations UYT

Carl Milbourne
Head of Operations
UYT
THE SOCIETY OF MOTOR MANUFACTURERS AND TRADERS LIMITED
PAGE 1
An overview of some successful
methods and strategies
Carl Milbourne
Head of Operations
Attitude
Innovation
People
Technology
Agility
Heritage
Corporate Profile
or Heritage
Press Facility Overview
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Robot or Manual
600t Tandem Press
600t Blanking Press
1800t Transfer Press
600t Progression / Transfer Press
200t Progression Press
Weld Facility Overview
 Spot Welding = 220
 Projection Nut Weld = 60
 Automated Mig Weld = 8
 Auto Nut Welder = 2
Accreditations
Evolution to Lean & Agile Manufacturing~
Volume & Investment Trend
Comment:As shown UYT has had many New Model
launches within a short period of time, each
one pushing towards a more lean/agile
manufacturing base.
Evolution to Lean & Agile Manufacturing ~ First big Milestone
Strategy Brief:To expand our Weld
Facility by 25%, this
allowed us to increase our
welding capacity and also
accommodate more
complex Structural parts.
Advantages:
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Linear line flow
Interchangeability
2001
“Core Comps”
“Hang on Parts”
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Door apertures
Sun roofs & panels
Tail gates
Bumper Beams
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Front Side Frames
Front Damper Housings
Front Bulkhead
Rear Side Frames
Front & Rear Wheel Arches
“Complete parts Range”
Evolution to Lean & Agile Manufacturing ~ Capacity Constraint's
Strategy Brief:Volume increases
placed pressure on
existing line layout. UYT
increased capacity to
accommodate volume
flex.
Advantages :
 Quicker cycle time
 Increase Output
 Flexibility of manpower
2006
Front to Front production
2004
2001
Back to back production
Evolution to Lean & Agile Manufacturing ~
Greater Press Portfolio
Strategy Brief:Greater press flexibility
was a key driver for
this phase. We
Expanded our Press
Facility by 50%
Advantages:
 Increase Product portfolio
 Increase Output
 Competitive Piece price
2004
Evolution to Lean & Agile Manufacturing ~ Space Constraint’s
Strategy Brief:With the rapid volume
increases UYT
experienced logistical
space was an issue. It
was necessary to
create a ‘Bonded’
warehouse for Int/Ext
product
Advantages:
 Inventory Accuracy
 Greater Buffer control
2006
Evolution to Lean & Agile Manufacturing ~
“Sowing the Seed”
Strategy Brief:Low Volume created an
Opportunity to increase the
flexible capability of our
Assembly lines. With Lines
being more efficient floor
space could be Utilised
towards our vision of “
Innovation line” basically
Benchmark line layout
Advantages
 Multi Variant lines
 Skill Versatility
 Floor Space Utilization
2010
Evolution to Lean & Agile Manufacturing ~ Innovation Lines
Strategy Brief:Amalgamation offered the
opportunity to free issue
the use of equipment into
the new modular lines.
This reduced amount of
new investment required
(£12M)
2011 Factory
Layout
2013
2012
Current Factory
Layout
Evolution to Lean & Agile Manufacturing ~ The transition……
Phase 1
Phase 2
2013
2012
Final layout
Phase 3
Phase 4
Evolution to Lean & Agile Manufacturing ~ Future Bottleneck
Strategy Brief:OEM’s are driving for a
more efficient car through
weight saving’s. High
strength steels are
becoming an important
factor for this.
However they require
bigger tonnage Press.
2016
2015
Advantages
 Remain Competitive
 Reduce piece part cost
 Potential to broaden
our customer range
3000Ton Press
Things you don’t plan for…….
Global
Recession
Key Facts:Significant downturn in Global Economy
Sterling devalued by some 30%
Automotive industry heavily effected
2013
(Luxury goods).
2012
Recession
Japan
tsunami
Thai
Floods
Key Facts:Extreme heavy rains in Thailand during
Sept & Oct. 2012. Most expensive natural
disaster in Thai history.
Significant Infrastructure damage
especially Industry.
x 1 fire
2011
Key Facts:March 11, 2011 - At 2:46pm, a 9.0
magnitude earthquake takes place 231
miles off Japan.
The earthquake causes a tsunami with 30 ft
waves that damage large area’s within
Japan.
Significant impact to Japan’s economic
infrastructure
2014
Thai floods
2008
Tsunami
UK Storms
Response to change
“Its not the strongest of the species that
survives, nor the most intelligent, but the
one most responsive to change”
Treat unplanned as an Opportunity to Improve-Back to Basics
2011
Auto Replenishment
2008
TPM across Plant
Inspection method improvement
 Quality up activities
 Parts control improvements
 Upskill 1st line management
1st Line management development
Treat unplanned as an Opportunity to Improve
“ Stronger constitution”
2012
Training Room / Centre
 Created a safe working environment
 Gain ideas from the general associates
 Promote best practice
5’s on Genba
5s on Genba
The Story so far………………..
2012
Flywheel
2013
2014 Target
Used to increase momentum
and thereby provide greater stability
or a reserve of available power
 Remove all Disturbance from the Genba
 No silo Management by Departments
 Strong Teamwork
UYT
Distraction
Hassel
Irritation
Disruption
Mr Mayumi-san
was a lone Nut
Trouble
UYT Gained Momentum
We don’t want to stop this movement!
To Start a Movement : Must be Public
 Easy to follow
 Embraced as equals
 It takes GUTS to be the first follow
 No movement without the first follower
Manchester UTD
UYT Ltd ‘Class of 2002’
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

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Craig Tidman
Mark Sabino
Operator  Q /Mgr Operator  P/Mgr
1999 – Won Champions league [Treble]
Best team in the World
Attitude/Work Ethic
Impact on the Business
Skills
Courage
Irreplaceability
Dave Ward
Operator  E/Mgr
David Jackson
Vish Dhand
Operator  W/Mgr Operator  Q/Mgr
All above started UYT as General associates
Bother
Disturbance
” An interruption of that
Upset
which is Normal or Regular”
Distress
Worry
Annoyance
Interference
Inconvenience
When things go Wrong look into the mirror
to see what you could of done better – Don’t
portion blame on others
When things go Right look out the window
to give praise – Don’t bask in the glory
The Story so far………………..
2012
Flywheel
2013
2014 Target
Used to increase momentum
and thereby provide greater stability
or a reserve of available power
 Remove all Disturbance from the Genba
 No silo Management by Departments
 Strong Teamwork
UYT
Distraction
Hassel
Irritation
Disruption
Mr Mayumi-san
was a lone Nut
Trouble
UYT Gained Momentum
We don’t want to stop this movement!
To Start a Movement : Must be Public
 Easy to follow
 Embraced as equals
 It takes GUTS to be the first follow
 No movement without the first follower
Manchester UTD
UYT Ltd ‘Class of 2002’





Craig Tidman
Mark Sabino
Operator  Q /Mgr Operator  P/Mgr
1999 – Won Champions league [Treble]
Best team in the World
Attitude/Work Ethic
Impact on the Business
Skills
Courage
Irreplaceability
Dave Ward
Operator  E/Mgr
David Jackson
Vish Dhand
Operator  W/Mgr Operator  Q/Mgr
All above started UYT as General associates
Bother
Disturbance
” An interruption of that
Upset
which is Normal or Regular”
Distress
Worry
Annoyance
Interference
Inconvenience
When things go Wrong look into the mirror
to see what you could of done better – Don’t
portion blame on others
When things go Right look out the window
to give praise – Don’t bask in the glory
Thank you for
Listening
Don’t forget to Visit
UYT stand (Stall 1)