BS/020416/SH-WZ(2000GB)ConfidentialEnhanceAssetProductivity,ProductQualityandDeliveryPerformancethroughLeanTransformation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。April24,2002DiagnosticPhaseProgressReviewBS/020416/SH-WZ(2000GB)2ExecutiveSummary•BaoSteelcurrentlyfacessignificantchallengesinsatisfyinggrowing,demandinganddifferentiatedcustomerneedsinabidtobecomeworld-classsteelcompany.Asthekeybottleneckpartoftheproductionchain,currentHRCperformanceonassetproductivity,productqualityanddeliveryperformanceneedstobesignificantlyimprovedforBaoSteeltosecureandstrengthenitscompetitivepositiontogrowmarketshareinanincreasinglycompetitiveenvironment(Challenges&Opportunities)Topdownbenchmarkingwithexternalandhistoricalinternalbestpracticesaswellasbottomuprootcauseanalysisrevealssignificantreductionpotentialinmaintenancetime,rollchangetime,breakdown,speedloss,rework(includingdowngrade),anddeliveryleadtime.Potentialnearterm(withinnext2years)financialimpactacrossallthreeareascouldreachRMBmillionintotal.Interviewsandperformanceethicssurveyalsoindicatedimprovementpotentialinorganizationalefficiencyandconsequencemanagement.(Diagnosticresults)BaoSteelshouldrealizesignificantimprovementpotentialandresultingfinancialbenefitswithinandacrossassetproductivity,productqualityanddeliverythroughacomprehensive3-5yearschangeprogram.Itshouldengageandempoweremployeesatoperationalleveltorigorouslyapplyleantoolsandstructuredproblemsolvingapproachtosetupsystemsandparticipativeprocessestopursue“Kaizen”.Tosupportleantransformation,BaoSteelshouldalsostrengthenitsorganizationalcapabilitybysettingupContinuousImprovementOrganizationaswellaspolicydeploymentsystemtoinstitutionalizethechangeprogram.ITsupportinselectedhighpriorityareashouldalsobedevelopedtosupportchanges.(Visionforimprovement)HRCshouldkickstartthechangeprogrambyimplementinga6monthspilotprogramimmediately.Itshouldpursuebreakthroughinitiativestoimproverollchangetime,maintenancetimeusingleantoolsaswellassettingupappropriateorganization,systemsandprocessesforcontinuousimprovementbysolvingaselectednumberofhighpriorityproductqualityandbreakdownproblems.ItshouldstartpolicydeploymentinparalleltoinstitutionalizethechangeprogramwithinHRC.ITsupportshouldalsobebuilttosupportimplementation.BS/020416/SH-WZ(2000GB)3TableofContentI.Challenges&OpportunitiesII.LeanManufacturingDiagnosticResultsIII.VisionforLeanTransformationIV.PilotPlanV.AppendixBS/020416/SH-WZ(2000GB)4BaoSteelispressuredtoincreaseitsHRCcapacityutilizationtomeetinggrowingdemandbothdomesticallyandinternationallysource:baosteelBaoSteelneedtoquicklyenhancecapacityutilizationtomaintainandgrowmarketshareHRC2001capacityutilization%57.761.377.474.6OEEcapacityutilization158020502001Production325.6万吨505.6万吨capacityutilizationBESTPRACTICEOEEBESTPRACTICE80-85%70-75%BS/020416/SH-WZ(2000GB)51.62.01.31.25.88.7BaosteelneedtocontinuouslyimproveproductqualitytomeeteverdemandingcustomerrequirementBaoSteelhasbeencontinuouslyenhancingcapabilitytomeeteverdemandingcustomerrequirements…资料来源:宝钢股份…HoweverHRCproductqualityremainsamajorproblemaskeyqualityindicatordeterioratedrecentlyReworkRate%8.79.6158020502000200120002001Downgraderate%1580205020002001200020011.93.1339471CustomerComplaintsnumberQualityCompensationtocustomerRMBYuan/10,000Yuan2000200120002001Custome...
