Agenda

I- APSYS

II- APSYS TOOLS & CONCEPTS

III- PEOPLE DEVELOPMENT

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Agenda

I- APSYS

II- APSYS TOOLS & CONCEPTS

III- PEOPLE DEVELOPMENT

www.rsgbestpractice.org
WHAT? APSYS Mission

APSYS = ? ALSTOM Production SYStem

Mission:

“Implement a common way of working on all sites

to fulfil the SQDC performance commitment with common,
sustainable, effective processes.”

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 WHY?

The APSYS principles

are based on those of Lean Manufacturing ...

• Eliminate waste
• Pull flow
• Make problems visible
• Create standards based on best practices
• Be involved in continuous improvement

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WHERE? - The APSYS Network – Services

Apsys Leaders LIST - 2015-10.

Haifa - Jerusalem (Israel)

0

Naperville (USA)
THOMPSON Jeffrey

Valle de Mexico
Ramirez Joab

Ridderkerk
Cabreuva (Brasil) 0
TOMINO Giselle Preston Bro (Sweden)
HOGGAN Laurence JONSSON Oskar
Manchester
MORRIS Jonathan
Dublin Warsaw
Neptuno (Chile) 0 PRUSAK Piotr
BURDILES-ARCE Jimmy Nottingham
0
Golders Green
HUNTER Lisa
Stendal (Germany) Algiers
MATERZOK Ralf (Acting) ABDI abdelhak

Le Creusot Braunschweig
MARQUES Carlos MOULES Jeremie (Acting)
Bucharest
RADU Mihai
Sesto (Italy)
PAFFETTI Alberto
Minuetto(Italy)
GATTI Andrea

Villeurbanne
0 La Sagra (Spain) Nola (Italy)
Tarbes MORA Pablo GRIFFI Paola
0

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UK&I APSYS Leader Locations

PRESTON

MANCHESTER

GOLDERS GREEN

WEMBLEY

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 HOW? APSYS roadmaps by Domain
From a tool box to a true philosophy…
2004 2009 2012 2015

Shop Floor
Supply Chain
Quality
Industrialisation
Management
Sourcing
Project (pilot)
Engineering (pilot)

Wave 8 Wave 11 Wave 14

Wave 1
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Agenda

I- APSYS

II- APSYS TOOLS & CONCEPTS

III- PEOPLE DEVELOPMENT

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QRQC : Quick Response Quality Control

• Tool Robust Containment

 Deep Root Cause analysis :
Ishikawa, 5 Why …

• Daily animation

• Mindset :
• Gemba / Genbutsu / Genjitsu
• Real place / real part / real data

 Use of QRQC tool for every issue - in every department

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SITE IMPROVEMENT PLAN

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SITE IMPROVEMENT PLAN

SWIP
Single Week
Improvement Program

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 Production APSYS BOARD
 Monitor our Performance during 5’meeting with relevant SQCD Indicators
 Better Visible Management : performance / non-performance, problems are not hidden, forgotten
!
 Fix problems rapidly
 Ensure TEAM responsibility, clarify responsibilities and accountabilities

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Standardised Operations

• High Process variation depot to

depot
• Introduction Of Standard
operation sheets
• Best known way to complete task
• Standardisation across depots
maintaining ;-
• Safety
• Quality
• Delivery
• Cost

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Agenda

I- APSYS

II- APSYS TOOLS & CONCEPTS

III- PEOPLE DEVELOPMENT

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 Lean Training Overview & Certification

• Three week training program :

• Wk1: Lean Toolkit
• Wk2: SWIP (Single Week Improvement Project)
• Wk3: Kaizen Instructor Training
• Certification
• Fulltime attendance on course
• Pass Lean Toolkit question paper (wk1) – 70% pass mark
• Successfully complete Lean project

A team embedded in each area of the business to act as

Ambassadors for Lean

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 Wk1 - Lean Toolkit Agenda
Lean Facilitator Training - Week 1 Agenda
08:00 08:30 09:00 09:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 16:45 17:00
Day
Previous cohort
Pulse
Lean Facilitator Policy Plug game -
1 Training Overview Lunch Management System Check
Project Deployment Simulation #1
Review
Presentation

Pulse
Review Lean Production System Plug game - Lean Production System - Plug game -
2 7-Wastes Lunch Check
of Day 1 - Part 1 Simulation #2 Part 2 Simulation #3
Review

Pulse
Review 5S Workplace Organisation & Process & Time Plug game -
3 Set-up Reduction Lunch Standard Operations Kanban Check
of Day 2 Visual Control Observation Simulation #4
Review

Pulse
Review Busines Process Kaizen Breakthrough Total Productive
4 Value Stream Mapping Lunch Lean Value Chain Check
of Day 3 Kaizen Methodology Maintenance
Review

Review Review &

5 Problem Solving Lunch
of Day 4 Test Paper

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Lean Training for Steering Committee
Standard Agenda – 2 Days

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Lean Training

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Lean Training - Tools covered

Understanding the need for kitting Understanding the need for 5S Understanding the need for
Indicators

Understanding the need for 5’ Understanding the need for Understanding the need for Task
Meeting Autonomous teams Sequence

+ 7 wastes, VSM, Improvement Plan, …

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Next Phase – Lean Learning Organisation

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APSYS Key Points

• Lean Manufacturing is not a tool box but a long-term philosophy.

• Lean Manufacturing seeks to satisfy our customers by producing with maximum
added value (optimisation of processes) and consuming minimum resources (waste
reduction).
• The motivation and involvement of people is
key to the success of Lean . Building a culture for success
• APSYS is the Alstom Production SYStem based in lean concepts.

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Questions ?

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