David Jacquart et Lionel Verchere présentent la façon dont ils ont démarré le Lean chez SOGEFI AC, en choisissant de démarrer simultanément en Production mais aussi au développement. Découvrez leur l'expérience, les succès, les apprentissages, mais aussi les difficultés rencontrées. Retrouvez les événements, master class et la librairie du lean management sur le site de l'Institut Lean France.

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering
…du Produit au Manufacturing Engineering
Paris, 9th April 2013
SOGEFI GROUP / Engine System Division / Air & Cooling / Orbey , March 2013
Manufacturing Air & cooling Production System
MAPS
Developping People First !

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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 SOGEFI Group
 MAPS, Historique et principales réalisations
 Un choix : celui d’embarquer de suite le développement et
l’ingénierie
 Le Lean en Ingénierie : participation aux HOSHIN, « Ingénierie
Carton », Slow Build, A3 Report, et les quelques décisions
prises comme le découplage et ses conséquences sur l’indus …
 L’Obeya Projet et Industrialisation
 Les Targets Cost Event
 Questions/Réponses
Sommaire

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering
 SOGEFI Group
 MAPS, Historique et principales réalisations
 Un choix : celui d’embarquer de suite le développement et
l’ingénierie
 Le Lean en Ingénierie : participation aux HOSHIN, « Ingénierie
Carton », Slow Build, A3 Report, et les quelques décisions
prises comme le découplage et ses conséquences sur l’indus …
 L’Obeya Projet et Industrialisation
 Les Targets Cost Event
 Questions/Réponses
Sommaire

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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SOGEFI
Sogefi is a world leader
in the design and
manufacturing of
engine filtration,
suspension vehicle
technologies
Sogefi owns a fully integrated
industrial process – from
engineering to manufacturing
to assembly – that guarantees
the best quality and
improvement of product
performance
Innovation drives
each of Sogefi’s
core businesses,
supported by
engineers and
technicians
in 9 R&D centers
across the world
SOGEFI, an Italian group on the Italian Stock Exchange, is a Worldwide
leader in the automotive parts industry, specialised in engine systems
and flexible suspensions components since 1980

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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SOGEFI
SOGEFI Group can provide to car manufacturers sub-
assemblies and complete modules with high added
value in the areas of air intake and cooling
AIR INTAKE & COOLING SYSTEMS
 Headquarter: Orbey, France
 Manufacturing locations : France, Romania,
Canada, Mexico, India, China and Brazil
 1200 employees
 312 M€ External Revenues in 2011

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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 SOGEFI Group
 MAPS, bref historique et principales réalisations
 Un choix : celui d’embarquer de suite le développement et
l’ingénierie
 Le Lean en Ingénierie : participation aux HOSHIN, « Ingénierie
Carton », Slow Build, A3 Report, et les quelques décisions
prises comme le découplage et ses conséquences sur l’indus …
 L’Obeya Projet et Industrialisation
 Les Targets Cost Event
 Questions/Réponses
Sommaire

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Manufacturing Air & cooling Production System
Developping People First !
v
vv
v
v

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Lean en Production
Lean en Conception des Moyens de Production
Lean en Conception Produit
Notre choix …

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous fait depuis 2009 ?
2009 Project start up
Benchmark and TOP Management training
Training Program : 400 employees / 4000 hours
Value Stream Mapping (VSM) in all Plants
Visual management : Parts board on all machines
Lean and Supply Chain departments created
Japan Study Tour at Toyota and Sensei
2010

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous fait depuis 2009 ?
Focus on Employees Empowerment
Team Leader Organization Launching
Management Visuel (Shop stock, Part Boards, Red Bin, …)
Kaizen : 1 Hoshin / month / plant
5S, Standardized Work, Red Bins, SMED and Kanban as common Tools
Pull System : Levelling, Truck Preparation Area / Pool Stocks,
Shop stocks are being to be implemented
2011

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous fait depuis 2009 ?
2011 Product / Process Developpment  Obeya Room
- Visual Managment Project
- Target Cost managing for major project

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Avec Quelle Dynamique ?
To reach a Lean Level, we have to do :
- Improve Customer Satisfaction
- Internal Quality … from 60 000 to 10 PPM
- Reduce Lead Time … to increase our Cash
- Standardized Work, to do all on right time …
… , for Production and Developpment

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Avec Quelle Dynamique ?
To Improve
Engineering
« simulation »
Pull Flow
HOSHIN
Let’s move the company !
- Customer Satisfaction
- Our JIT Conditions
- Our JIDOKA
- Our Standardized Work
The leader is the Plant …
… because Added Value is created by the Plant !
Co-Conception
Product/Process
Target Cost
Management
HOSHIN

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous appris ?
A HOSHIN Plan for all Plants
This is the Key for our Lean Plan :
- Training to production team (Supervisors and Team Leader)
to reset our production cells :
 Improve Operators Work Conditions
 Takt Time for each production cell
 Improve Internal Quality on the shop floor (internal ppm)
 Operators empowerment with Standardized Work

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous appris ?
100 HOSHIN :
- 1500 Ergonomy issues fixed
- Internal Quality : - 50% Internal ppm
- Lead time decrease : - 20% / year
- Standardized Work done with Operators
- Direct Labor Efficiency Improvment : + 20%
- A real « Flight simulator » for Engineering Dpt who participe at
each Workshop

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous appris ?
A “Flight Simulator” for Engineering … The HOSHIN workshop done before launch
- Material and Information Flow Analysis and A3 report / project
- Data base for Time standard (MTM2) and Standardized Machine
- Standardized work for each new Production line, Slow Build and “Ingénierie Carton”
- Standardized Work at Engineering Dpt (Technical's Meeting each Friday, …)
 Improve Customer Satisfaction (Production)
 Improve internal Quality (capability machine)
 CAPEX Reduction (more flexibility)
 Reduce the Engineering Lead Time
 Technical Expertise Improvment

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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ENSEMBLE
OUTILS
PRODUCTION
CONCEPTION PROCESS
« METHODES »
Apprentissage … Le métier
• Participation aux chantiers Hoshin
Capitalisation des bonnes pratiques et les intégrer dans l’ingénierie des nouveaux produits
• Amélioration de l’Ergonomie des postes de travail et validation avec CAP TMS
• Industrialisation Carton
Maquetter avec les opérateurs pour optimiser les flux et l’ergonomie.
• Slow Build (avec des fournisseurs de moyens)
Analyser les opérations d’assemblage pour les optimiser

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Apprentissage … Le métier
• Target Cost
Participation aux Event pour optimiser le coût total du produit, et consolider la marge
• Plan d’innovation : pour séparer l’innovation des développements
• Set-based : Etude de toutes les solutions pour ne pas prendre des décisions trop tôt qui créent
des surcoûts.
• A3 d’industrialisation : Etablir la communication avec l’usine et challenger les équipes avec des
objectifs communs.
• Travail standardisé : Définir le guide d’utilisation du process pour le manager de production
• Machine standards : standardiser pour diminuer les CAPEX et intégrer les besoins de la
production

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Apprentissage … Le métier

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering
Apprentissage … Le métier

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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Qu’avons-nous appris ?
Improve the Product/Process Co-Conception to reach Targets Cost
OBEYA Room created :
- Visual Management for major projects
- Target Cost Management
- Understand the Real production problems
- Research and Development Standardized Work

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Du Produit au Manufacturing Engineering
Qu’avons-nous appris ?
Improve the Product/Process Co-Conception to reach Targets Cost
 Improve the Customer Satisfaction and developing our business
 Reach Targets Cost
 Improve Quality
 Reduce the R&D Lead time
 Improve our Technical and “know how” Expertise

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ILF /Journée Lean en Ingénierie / DJ, LVParis, 9 Avril 2013
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
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www.sogefi.it
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FOR YOUR ATTENTION