Process optimization and introduction of a management system
for optimizing results (Continuous Improvement System) for an international medium-sized company in the automotive battery sector (Automotive Supplier Tier 1) in the role of Director Continuous Improvement
Company: Johnson Controls Autobatterie GmbH & Co KGaA
Industry:
Automotive, car batteries
Turnover figure:
n.a.
Number of employees:
approx. 3,400 (EMEA)
Company headquarters:
Hanover
Internet:
www.clarios.com
Situation at the client:
- Competition leads to high cost pressure
- Required cost reductions are not reliably achieved
Area of responsibility:
- Director Continuous Improvement
Task:
- Development of a system for continuous and predictable improvement in results
- Systematic identification, realization, and tracking of projects and initiatives for improving results
- Development and training of appropriate resources
Measures:
- Gradual introduction of an integrated system across all areas and levels of the production plants
- Development and training of a central team and teams in the plants (Six Sigma, Lean)
- Introduction of target-oriented group work at the shop floor level
(High Performance Teams) - Revision of the idea management system (Innovation System)
- Structured approach to identifying potential for improvement (Gap Analysis)
- Regular implementation of standardized workshops (Acceleration Programs)
- Active management of project portfolios for each location
- Connection to cost accounting to ensure actual achievement of goals, including cross-site consolidation
Successes:
- Predictable and consistent improvements in results
- Increase in productivity (up to 8% p.a.), reduction in waste (up to 15% p.a.)
- Significant improvements also in the areas of quality, customer satisfaction, and health
Special challenge:
- Cultural resistance in the plants to the change process was overcome, among other things, through good results and development opportunities for employees
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