This is AMP Today

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SMART CAR. SMART PEOPLE. SMART COMPANY.
Lean Concepts to Meet Value-adding Activities
By Carlos Eduardo DaSilva
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SMART CAR. SMART PEOPLE. SMART COMPANY.
TYCO ELECTRONICS IN PROFILE
Tyco Electronics is the world-leading supplier of
passive electro-mechanical components. The
high-tech products of its brands like AMP, ASG,
EC, Elcon, Elo TouchSystems, HTM, M/A COM,
Madison Cable, Netconnect, Raychem, SIMEL,
Schrack, OEG and PB have been used in various
applications of the following sections
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SMART CAR. SMART PEOPLE. SMART COMPANY.
Tyco International Tyco Electronics M/A
COM www.macom.com Microwave Solutions Business
Unit Automotive Sensors and Telematics Group
DISTRONIC ADAPTIVE CRUISE CONTROL ACC Lab
Lowell , MA
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE CUSTOMERS
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE PRODUCT
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Data transformed becomes information.Information
transformed becomes intelligence.Intelligence
transformed becomes competitive advantage.
SMART CAR. SMART PEOPLE. SMART COMPANY.
HOW TO MAKE THE CHANGE
QUALITY AS RESULT OF HUMAN EXCELLENCE
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SMART CAR. SMART PEOPLE. SMART COMPANY.
TRANSITION CYCLE
GROUP BEHAVIOR / ORGANIZACIONAL
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE PLAN
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE ACTION
PEOPLE
PEOPLE
PEOPLE
PEOPLE
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SMART CAR. SMART PEOPLE. SMART COMPANY.
KEY LEAN CONCEPTS
Plant Level
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE BENCHMARK
T
P
S
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE BENCHMARK
T
Thinking
Toyota
Production
System
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE ISO APPROACHED
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE PLAN
Database
Reports
MRB
Metrics
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE RESULT

• REAL TIME INFORMATION
• REAL TIME KNOWLEDGE
• REAL TIME DEFECT IDENTIFICATION
• REAL TIME CICLE TIME
• REAL TIME COST OF POOR QUALITY
• REAL TIME PROCESS VARIABLE STUDY
• REAL TIME TEAM WORK

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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE MANAGEMENT
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE MANAGEMENT
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE MANAGEMENT

Quality Management






Quality Assurance







Quality Control

















IPI

OPERATOR LEVEL







IPI ENGINEERING REVIEW LEVEL



IPI MANAGEMENT REVIEW LEVEL




Effectiveness
Efficiency
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SMART CAR. SMART PEOPLE. SMART COMPANY.
When we talk about defects in our factories, we
are talking about defective processes. If
theres a defective process, its going to turn
out defective products. However hard you examine
a defective product, it doesnt improve the
process. So we should focus on defective
processes. Components move from supplier to
supplier in a flow, and unless an excellent
control system is in place, its impossible to
prevent defects from occurring.
Teruyuki Minoura, Former President, Toyota Motor
Manufacturing, North America
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE PLAN
2002
Project A
Project B
Project C
2003
2005
IPI KNOWLEDGE SYSTEM
COMAKERSHIP SUPPLIER MANAGEMENT
Tools Balanced Scorecard 6Sigma
Corrective/Preventive Actions Notification
Audits (System/Process/Product) Recognition
Program etc.
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SMART CAR. SMART PEOPLE. SMART COMPANY.
WHAT IS CO-MAKERSHIP ?
Its the establishment of a relationship
management between Customer and Supplier to
achieve the extremely value add and the total
customer satisfaction, through Quality
Agreement Lean Supply Chain Just in Time
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE SUPPLIER RELATIONSHIP
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE GUIDE
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE AGREEMENT
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE PLAN
2002
Project A
Project B
Project C
2003
2005
IPI KNOWLEDGE SYSTEM
COMAKERSHIP SUPPLIER MANAGEMENT
VISUAL FACTORY
Tools Balanced Scorecard 6Sigma
Corrective/Preventive Actions Notification
Audits (System/Process/Product) Recognition
Program etc.
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SMART CAR. SMART PEOPLE. SMART COMPANY.
THE FIVE COMMON SENSE
The Principle is Clean it up, Make it Visual

• Sort Sort through items and keep only what is
  needed while disposing of what is not
• Straighten (orderliness) A place for
  everything and everything in its place
• Shine (cleanliness) The cleaning process often
  acts as form of inspection that esposes abnormal
  and pre-failure conditions that could hurt
  quality or cause machine failure
• Standardize (create rules) Develop systems and
  procedures to maintain and monitor the first
  three Ss
• Sustain (self-discipline) Maintaining a
  stabilized workplace is an ongoing process of
  continuous improvement

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SMART CAR. SMART PEOPLE. SMART COMPANY.
VISUAL AID CONTROL
The Principle is Can our manager/director walk
through the shop floor or office, and recognize
if standard work or procedures are being followed?
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SMART CAR. SMART PEOPLE. SMART COMPANY.
DONT PUSH, JUST PULL
The Principle is From the inspiration of
supermarket - Instead of using a system of
estimated replenishment, the store restocks only
what has been sold, thereby reducing defective
inventories. The KanBan System is the most
critical to implement a TPS model.
The more inventory a company has,the less likely
they will have what they need. Taiichi Ohno
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SMART CAR. SMART PEOPLE. SMART COMPANY.
DEVELOPING PEOPLE AND PARTNERS
CUSTOMER
Supplier
Automotive Group
Floor
FOCUS
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SMART CAR. SMART PEOPLE. SMART COMPANY.
SUMMARY
This is the result of manufacturing science
transitions that we have been working on for at
least five years Bill Guggina Operations
Manager Delphi Delco Electronics
Systems Kokomo-IN-USA