Enhance Capacity Stability … through Lean Transformation for Bao Steel .pptVIP免费

BS/020416/SH-WZ(2000)CONFIDENTIALEnhanceCapacityStability&Utilization,ProductQualityandAccuracy&TimelyDeliveryPerformancethroughLeanTransformationThisreportissolelyfortheuseofclientpersonnel.Nopartofitmaybecirculated,quoted,orreproducedfordistributionoutsidetheclientorganizationwithoutpriorwrittenapprovalfromMcKinsey&Company.ThismaterialwasusedbyMcKinsey&Companyduringanoralpresentation;itisnotacompleterecordofthediscussion.April24,2002LeanManufacturingDiagnosticPhaseProgressReviewBS/020416/SH-WZ(2000)2TABLEOFCONTENTI.LeanManufacturingDiagnosticResultsII.BaoSteelLeanTransformationApproachBS/020416/SH-WZ(2000)3BaoSteelispressuredtoincreasethecapacityutilizationofitsHRC,currentlythekeyandbottleneckpartofBaosteel’sproductionprocessistomeetgrowingdemandbothdomesticallyandinternationallySource:Baosteel,TeamAnalysis,McKinseysteelexpertsinterviewsBAOSTEELNEEDTOQUICKLYENHANCECAPACITYUTILIZATIONTOMAINTAINANDGROWMARKETSHAREHRC2001capacityutilization%57.761.377.474.6OEEcapacityutilization158020502001Production3.256millionton5.056milliontonCapacityutilizationbestpracticeOEEbestpractice80-85%70-75%BS/020416/SH-WZ(2000)41.62.01.31.25.88.7BAOSTEELNEEDTOCONTINUOUSLYIMPROVEPRODUCTQUALITYTOMEETEVERDEMANDINGCUSTOMERREQUIREMENTBaoSteelhasbeencontinuouslyenhancingcapabilitytomeeteverdemandingcustomerrequirements…Source:Baosteel…there’ssomegapvs.everdemandingcustomerrequirementsonqualityandhistoricalbestlevel.ReworkRate%8.79.6158020502000200120002001Downgraderate%1580205020002001200020011.93.1339471CustomerComplaintsnumberQualityCompensationtocustomerRMBYuan/10,000Yuan2000200120002001CustomerRequirementsHRCqualityenhancement•Onecustomer’srequirementsforsurfacequalityarehighashotrolledplatesareusedasitsproductfaceplates–dot：<3within1metervertically,area<3mm2，depth<0.5mm–scratch：length<5mm•Onecontainer-producingcustomer’srequirementsforshapewavearehigher–Forplateswiththickness2mm,requirementforshapewavehasbeenimprovedfrom15mmto10mm–Forplates>2mm,requirementforshapewavehasbeenimprovedformQ/BQBstandardto15mm•Applythemostappropriatefurnacetappingtemperature;adduppersurfacecleaningdeviceandlowersurfacecleaningdevicetothickplatefettlingline•Fettle,checkandadjuststaightener•Customizefettlingoperationtechnologyaccordingtocustomerrequirements•Studycontrolofthicknessspecificationsandstripshapeofrollinglineandrenovateconvexityinstrument•Improvestripshapecontrolofdifferenttypesoflevelingmachines•Improveinternalcontrolandpassstandardofshapewave4.34.1Best3monthmovingaverage0.81.1BS/020416/SH-WZ(2000)5BAOSTEELNEEDTOENHANCECURRENTDELIVERYPERFORMANCETOMEETDIFFERENTIATEDCUSTOMERNEEDSSource:SalesDepartmentofBaosteelBaosteelshouldnotonlyreducedeliverytimeandfluctuationbutalsobuildcapabilitytoprovidestabledeliveryperformanceinregardtodifferentcustomersinordertolockupandoptimizecustomersegments.HRCDeliveryPerformanceDay19.734.3Mfgleadtime(D41-D51)Deliveryleadtime（D14-D51）=10.415.6OTIF(Weeklydelivery,Atypecontract)Contractualdeliverydate-20-15-10-7510152025303522%OTIF(Monthlydelivery)60-60-3030Contractualdeliverydate94%AdvanceOverdueAdvanceOverdueBS/020416/SH-WZ(2000)6SIGNIFICANTNEAR-ANDMED-TERMFINANCIALBENEFITCANBEACHIEVEDBYREALIZINGTHETHREEIMPROVEMENTPOTENTIALS*Calculatedfromthetimeforchangingworkrolleachtimefortwoweeksinthecomputersystem**Thepotentialforproductqualityimprovementis...