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transcript
Aalto 25.9.2017
ESI&Value Engineering
KARI TUOMINEN
© 2017 Konecranes. All rights reserved.
COMPANY IN NUMBERS
2
18,000 EMPLOYEES
600LOCATIONS
WORLDWIDE
ACTIVE IN ALMOST
50COUNTRIES
EQUIPMENT IS
60%OF TOTAL SALES
SERVICE IS
40%OF TOTAL SALES
2.0MILLION ANNUAL
SERVICE CALLS
OVER
14,000REMOTE
CONNECTIONS
MAINTENANCE
CONTRACTS
COVERING MORE THAN
740,000EQUIPMENT OF
DIFFERENT MAKES
€3.4 BILLION IN SALES
IN 2015
© 2017 Konecranes. All rights reserved.
A GLOBAL COMPANY
3
Region Americas HQ
Springfield, Ohio
Corporate HQ
Region EMEA HQ
Hyvinkää, Finland
Region APAC HQ
Shanghai, China
© 2017 Konecranes. All rights reserved.
CUSTOMER INDUSTRIES
4
SHIPYARDS
POWER
CONTAINER HANDLING
PETROLEUM AND GAS
MININGGENERAL MANUFACTURING
AUTOMOTIVEPAPER AND FORESTWASTE TO ENERGY AND BIOMASS
METALS PRODUCTION
© 2017 Konecranes. All rights reserved.5
OVERHEAD CRANES
STRADDLE CARRIERS
FORKLIFT TRUCKS COMPREHENSIVE SERVICE
INDUSTRY APPLICATIONS
SHIP-TO-SHORECRANES
NUCLEAR CRANES
GOLIATH SHIPYARD CRANES
WORKSTATION LIFTING SYSTEMS
YARD CRANES
REACH STACKERS
OUR PRODUCTS AND SERVICES
© 2010 Konecranes. All rights reserved. Kari Tuominen6
EARLY SUPPLIER INVOLVEMENT
ROLE
Konecranes
Suppliers
ESIProduct
Development
Product Process
Product & Service lifecycle
Delivery Process
Konecranes Supplier Base
Customer
Deliveries
&
Service
© 2010 Konecranes. All rights reserved.
Extent to which spec. is fixedCost to make technical changesProcurement impact on spend
ESI (Early Supplier Involvement)
EPI (Early Purchasing Involvement)
Cost
High
Low
Product-
design
Production
planningProduction
TimeSpecification
Early Procurement Involvement Offers Big Savings Potential
© 2010 Konecranes. All rights reserved.
EARLY SUPPLIER
INVOLVEMENT
Advantages
• Shorter project developmentlead times
• Improved perceived productquality
• Savings in project costs
• Better manufacturability
• Shared knowledge and learning
• Improved R&D efficiency andeffectiveness
• Accessibility to suppliers‘ technical capabilities
02/20/2012 DGS presentation / Kari Tuominen8
© 2010 Konecranes. All rights reserved.
STRATEGY – IDENTIFY MAIN ACTIVITIES
PRIMARY SOURCING TOOLBOXX. CATEGORY
Exploit Buying Power Create an Advantage
Consolidate number of
suppliers
Pool volume/variants across
units
Redistribute volume among
suppliers
Combine volume from different
commodity groups
Compare “total” costs
Model “should-costs”
Renegotiate prices
Unbundle pricing
Expand geographic supply base
Develop new suppliers
Profit from global supply/demand imbalances
Establish/develop key suppliers
Employ strategic alliances/partnering
Examine strategic make-versus-buy
Develop integrated supply chain
Reengineer joint processes
Share productivity gains
Integrate logistics
Support supplier operations improvement
Conduct product value analysis and engineering
Substitute materials
Buy standard materials
Optimize life cycle costs
Global
Sourcing
Best Price
Evaluation
Volume
Concentration
Product
Specification
Improvement
Joint Process
Improvement
Relationship
Restructuring
StrategicSourcing
B
V
J
R
P
G
Fill the square before those tools that you believe
will be most important within your category
(right mouse-click on field: fill & borders)
9 2011-03-07 Konecranes Academy
© 2010 Konecranes. All rights reserved.
Collaboration
idea.konecranes.com
BU 1/Q
Research
Agents 1/Q
INNOVATION MANAGEMENT
Local
processes
Research
process
Product
process
Idea
development
processes
Ideasfrom
employees
Ideasfrom
suppliers
Innovation culture
- Innovation contest- Communication
- Rewarding
Steering- Lead challenges
Customer studies
NeedsfromBU´s
NeedsFromfield
Volunteer based ~1% of working time
Innovation agent netw
ork
Decision
making
Innovation
ProductsServicesProcessesImprovementsNumber of ideas
annually: ~350
Number of comments: ~900
Number of contributors: ~500
Supplier Innovationaward
NEA 6SEAP
6AME
15IMEA 8
EUR 17
Tot. 52Ideation and innovation is everyone’s ”job” and idea.konecranes.com is a tool for managing the ideas.
Please, continue building positive innovation culture – everyone can share their ideas!
© 2010 Konecranes. All rights reserved.
Prescreened ideas
9/6/2017 Supplier Innovation Award 2010 / Tuomas Rekola11
© 2010 Konecranes. All rights reserved.
Q4
KONECRANES SUPPLIER INNOVATION AWARD 10/11
9/6/2017 Konecranes Supplier Innovation Award 10/1112
Konecranes
Supplier Day
2010
Konecranes
Supplier Day
2011
Konecranes Supplier Innovation Award 10/11
Generating
ideas, finding
alternatives
Analyzing
the
results
Evaluating,
selecting and
implementing
ideas
2010 2011
Q3 Q1 - Q2 Q3
Common cross-
functional
meeting
Host-driven process to get
ideas evaluated and
implemented
© 2010 Konecranes. All rights reserved.
ACTIVITY BY CATEGORIES
Category (No. of suppliers) Everything OK Some activity No activity
Electrical components (11) 6 4 1
Indirect materials (11) 6 5 0
Logistics (11) 4 6 1
Mechanical components
(12)
11 1 0
Parts subcontracting (10) 7 3 0
Steel (13) 11 2 0
TOTAL 45 21 2
Konecranes Supplier Innovation Award 10/119/6/2017 13
© 2010 Konecranes. All rights reserved.
GENERATED IDEAS
9/6/2017 14
EXAMPLES
• Embossed symbols in pendant
• Recycling of scrap material
• Annual supplier satisfaction surveys
• Start/stop -function for engine
• Using remote radio controllers in big port cranes
• User identification
• Administration of packaging material for outgoing goods
• Using preassembled parts
Categories (No. of
suppliers)
Generated ideas
Electrical
components (11)
~ 15
Indirect materials
(11)
~ 25
Logistics (11) ~ 5
Mechanical
components (12)
~ 60
Parts
subcontracting (10)
~ 30
Steel (13) ~ 50
TOTAL > 185
Konecranes Supplier Innovation Award 10/11
© 2010 Konecranes. All rights reserved.
POURING CAST ROTORS
REPLACED WITH THE
DIE-CASTED ROTORS
9/6/2017 15 Konecranes Supplier Innovation Award 10/11
•Replacing the pouring cast rotors with the die-casted rotors that are made in two pieces
IDEA DESCRIPTIONIDEA DESCRIPTION
•Manufacturing pouring casted rotors is time-consuming and requires a lot of work. On the other hand, manufacturing large die-casted rotors in one piece is expensive.
•The die-casted rotors can be manufactured with a reasonable price in two pieces
BEFORE AND AFTERBEFORE AND AFTER
•Higher quality and time-savings by using die-casting
•Utilization of existing instruments
•Avoiding the high costs of manufacturing die-casted rotors in one piece
BENEFITSBENEFITS
© 2010 Konecranes. All rights reserved.
•Purchasing subassemblies of the reach stacker frame abroad in container-sized units and doing the final welding in Sweden
IDEA DESCRIPTIONIDEA DESCRIPTION
•Before the manufacturing was done in Europe with high costs
•Now the subassemblies are purchased in large sets abroad with lower costs
BEFORE AND AFTERBEFORE AND AFTER
•Savings: 10-15%
BENEFITSBENEFITS
PURCHASING SUB-
ASSEMBLIES FOR
REACH STACKER
9/6/2017 16 Konecranes Supplier Innovation Award 10/11
© 2010 Konecranes. All rights reserved.
CANOPY FOR
STRADDLE POWER UNIT
9/6/2017 17 Konecranes Supplier Innovation Award 10/11
•To replace the complex cover of the straddle power unit with a sliding canopy
IDEA DESCRIPTIONIDEA DESCRIPTION
•The current multi-hatch cover is complex and assembled from many pieces
•In the new concept the canopy is made from two main pieces that can be slid open
•Larger access hatches make serviceeasier
BEFORE AND AFTERBEFORE AND AFTER
•Easier to maintenance
•Gives cover and protection
BENEFITSBENEFITS
© 2010 Konecranes. All rights reserved. 9/6/2017 Presentation Name / Author18
© 2010 Konecranes. All rights reserved. 9/6/2017 Presentation Name / Author19
STRIPTEASE PROJECTS
© 2010 Konecranes. All rights reserved. 9/6/2017 Presentation Name / Author20
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
TRIZ
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
TRIZ:(TEORIYA RESHENIYA IZOBRETATELSKIKH ZADACH)
THEORY OF INVENTIVE PROBLEM-SOLVING
It doesn’t matter how many resources you
have. If you don’t know how to use them, it will
never be enough.
Theory
Paradigm
Approach
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
WRONG PROBLEM SET UP
• Logically if we are solving a wrong problem, it won’t lead us to a goodsolution.
• We need to have a proper way to analyze the problem.
“If I had only an hour to save the world, I would spend fifty-five minutes defining the problem, and only five
minutes finding the solution.”– Albert Einstein
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
Overall Approach:
Somebody, someplace, has already solved your problem or one similar to it. Creativity means finding that solution and adapting it to the current problem.
Overall Approach:
Somebody, someplace, has already solved your problem or one similar to it. Creativity means finding that solution and adapting it to the current problem.
FINDINGS
Remove contradictions
Take advantage of hidden and idle resources
Gets closer to ideal solution
Good ideas
Trends of engineering system evolution stay constant
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
TRIZ has shared in the success of hundreds of
companies and individuals worldwide.
INDUSTRY TRIZ USERS
http://www.envisage-consultancy.com/clients.htm A.Kynin Examples MLCC-100831
© 2016 Konecranes. All rights reserved.© 2016 Konecranes. All rights reserved.
SET OF TOOLS
Component Analysis
Interaction Matrix Function Modeling Trimming
Function-Oriented Search (FOS)
Ideal Final Result Contradictions Triz Matrix
40 InventivePrinciples
Cause-Effect Chain Analysis
Trends of Engineering
System Evolution(TESE)
9 Windows
Small Little People
76 Standard Solutions
Substance FieldAnalysis
…and somemore…
Set of tools have been created
5T TROLLEYSUBASSEMBLY
by Kari Tuominen and Adeyinka Abass
17.11.2016
© 2015 Konecranes Plc. All rights reserved.© 2015 Konecranes Plc. All rights reserved.
1.3 FUNCTION MODELING
Motor
Pulley
Support Beam
Trolley Frame
Beam
BracketsWheels
Covers
BuffersShafts
Support
Beams
Drive Shaft
Connection Rod
Holds Holds Holds
Holds
Holds
Holds
Rotates
Rotates
Covers bearing and gearsHelps in assemblying and maintaining right distanceHold the pulley/sheave assembly
© 2015 Konecranes Plc. All rights reserved.© 2015 Konecranes Plc. All rights reserved.
5.1 RADICAL TRIMMING
Motor
Pulley
Support Beam
Trolley Frame
Beam
BracketsWheels
Covers
BuffersShafts
Support
Beams
Drive Shaft
Connection Rod
Holds Holds Holds
Holds
Holds
Holds
Rotates
Rotates
Hold the pulley/sheave assemblyCovers bearing and gears Helps in assemblying and maintaining right distance
Plates
© 2015 Konecranes Plc. All rights reserved.© 2015 Konecranes Plc. All rights reserved.
5.1 RADICAL TRIMMING
Motors
Wheels BuffersShafts
Support
Beams
Holds Holds Holds
Holds
Holds
RotatesHold the pulley/sheave assembly
Covers bearing and gears
Helps in assemblying and maintaining right distance
Plates
Covers
Covers bearing and gears
© 2017 Konecranes. All rights reserved.
NANB new trolley
idea
In new idea we plan to use side plates to
replace load beams and RHS
31
© 2010 Konecranes. All rights reserved. Kari Tuominen32
SHIFTING FROM COMMODITY TO
VALUE SOURCING
PAST
• Commodity experts
• Components
• Multiple tactical suppliers
• Stable raw material markets
• Fragmented supply chains
• Supplier delivery
• Price driven
• Tactical people competencies
TODAY-FUTURE
• Business relationship experts
• Modules / Systems
• More strategic suppliers
• Highly volatile markets
• Supply clusters
• Supplier value / ESI
• Total cost of ownership
• Increased focus on leadershipand project management
© 2010 Konecranes. All rights reserved.
THE BEST-OF-BEST SUPPLIER CAN IMPROVE OUR
VALUE PROPOSITION
• Own long-term strategic plan with a clear
desire of position in the value chain
• Understand Konecranes’ customer and
development needs
• Passionate attitude across supplier company
to build and deliver customer satisfaction
• Strives for long-term business relationships
• Proactively delivering / suggesting business
improvements and can challenge
Konecranes
• Takes full accountability for own supply
chain‘s development and performance
• Supplier‘s customer portfolio, <50 % with
one customer. Risk management and low
dependency
33 2011-03-07 Konecranes Academy
© 2010 Konecranes. All rights reserved.
WE ARE ENTERING THE SERIES OF LEGS OF
OUR PROCUREMENT CHANGE JOURNEY
From doing things …
… the yesterday's way … more efficiently … to doing them differently
34 2011-03-07 Konecranes Academy