BS/021110/SH-SG(2000GB)第六阶段工作成果报告文件机密January15,2003此报告仅供客户内部使用。未经麦肯锡公司的书面许可，其它任何机构不得擅自传阅、引用或复制。ImproveHRM’sproductquality,OEEandstabilitywithleanmanufacturingBS/021110/SH-SG(2000GB)2Executivesummary•UndertheleadershipofBaosteelleanmanufacturingsteercommittee,HRMhasachievedsignificantoperationimprovementduringthesixmonthpilotperiodwithgreateffortsfromdepartmentsinsideandoutsideHRM.HRMhasgreatlyincreaseditsOEEthroughtheimprovementeffortsinquality,rollchangeandmaintenance.Inaddition,sixlongtermkeyqualityproblemsallimprovedinpilotperiod.Moreimportantly,HRMhasgraduallybuilditsoperationalimprovementcapabilitiesthroughoutthepilotingprocess.LeantoolsandimprovementmethodswerewidelyusedinHRMinsolvingproblems.Moreover,leanandsixsigmatoolswerecombinedinsolvingsomequalityproblems.Inordertosustainthepilotresultsandensurethecontinuousimprovementefforts,HRMalsomadechangesinitsperformancemanagementsystemandbeguntheimplementationsincebeginningofthisyear.HRMhassetclearoperationaltargetsfor2003tofurtherimproveproductqualityandOEE,mainlythroughcontinuousimprovementinmaintenancetime,productqualityandspeedloss.•BasedonthesuccessofHRMpilot,Baosteelshouldquicklydesignandrolloutanoperationalimprovementprograminordertobetterpositionedforfuturechallenges.ThisoperationimprovementprogramwillmainlyconsistaseriesofimprovementprojectscarefullyselectedbasedonBaosteelownbusinessstrategyandfinancialgoals.Astandardproblemsolvingapproachwillbeusedcompanywide,withsixsigmatoolsinqualityproblems,andleantoolsinotheroperationproblems.Atsametime,thoseimprovementprojectswouldprovideatraininggroundforagroupofBaosteelownimprovementexperts.ESIwillbeplayamajorroleindrivingthisoperationimprovementprogramforward,McKinseycouldprovidemanyformsofsupportbasedontheneedofBaosteelandrolloutprogress.BS/021110/SH-SG(2000GB)3Agenda•HRMLeanPilotProgressOverview•BaosteelOperationalImprovementRollOutPlanBS/021110/SH-SG(2000GB)4OEE*20012002(Jan~Jun)2002(Jul~Dec)20012002(Jan~Jun)2002(Jul~Dec)1580205057.7%64.8%69.4%61.3%66.0%67.2%BefPilotAftPilot*:速度损失假设保持2001水平，年修时间按年修周期分摊计算Financialimpactrealizedthroughpilot10,000RMB4,5581,3635866,507RollchangeMaintenanceQualityTotalIfimprovementachievedcouldbesustained,theannualizedimpactis150millionRMBHRMhassignificantlyimproveditsOEEandrealizedsignificantsavingthroughleanpilotBS/021110/SH-SG(2000GB)519614896.1%97.1%74.553SIGNIFICANTIMPROVEMENTSCAMEFROMPRODUCTQUALITY,MAINTENANCEANDROLLCHANGERidgecoldrollingdowngrade（1580）tonJan-Jul,2002averageAug-Dec.2002AverageScalehotrollingfinallock-out（2050）tonJan-Jul,2002averageAug-Dec.2002AverageWidthhotrolllock-out（1580）coilJan-Jul,2002averageAug-Dec.2002AverageFoldingedge/edgedamagetemplock-out（2050）%Jan-Jul,2002averageOct-Dec.2002AverageRollingcracktemplock-out（1580）%Jan-Jul,2002averageOct-Dec.2002AverageThicknessprecision（2050）%Jan-Jul,2002averageOct-Dec.2002Average161510Workrollchange(minutes)1580Currentlevel（Verystable2050Maintenancetime:actual/plan15802050Target90%64.5Backuprollchange(hrs)MajorrollMinorroll158020505hrs/guide2.2hrs/guide1580FMentryguideInitialdowntimeExpecteddowntimeafterimplementation4.7hrs3.2hrsUnplannedbreakdownmaintenance-55%InitialdowntimeExpecteddowntimeafterimplementation2050FRollingMill₁1009389989897928385828893Target90%6/187/167...
