History of Continuous Improvement at Visteon

Ford Plan
Production VOS
EI Programs Lean Run
Employee Involvement System Thinking
Change

Deming VBOS
VMOS
PDOS
MMOS
Statistical QOS Work Teams Six Sigma
VPS FOS
Process White Boards Small Group
Control Activities etc.

Tools Thinking

Six Sigma

© Visteon Corporation GB-Mod #1 Rev 3.6 10/03 1

 Metodología Lean Six Sigma

Problemas resueltos con Lean

Problemas resueltos con Six Sigma
o Perdidas o desperdicios elevados
o Minimizar variación en los procesos
o Mejora de flujos de actividades
o Reducir las fallos y errores hasta 3.4 ppm
o Agilizar los procesos
o Six
Solución
Sigma científica de problemas
o Evitar errores humanos
o Enfoque a problemas y mejoras de calidad
o Enfoque a mejora de la productividad
© Visteon Corporation GB-Mod #1 Rev 3.6 10/03 2
 LEAN MANUFACTURING IS:

 Overall operational philosophy relative to daily management of

operations
 System Based tools to improve processes
 Drives continuous, incremental improvement

Continuous Flow / U Shaped Cells Standardize Work / Shop Floor Kaizen

Synchronous Production (JIT)
Pull Systems (Kanban)
Production Smoothing
Level Production / Line Balance
(hiejunka)
Value Stream Mapping
Produce to Takt Time
Metrics
DTD
OEE
FTT
Problem Solving - PDCA
Jidoka - Autonomation, PokaYoke, Andon
Mistake proofing -PokaYoke
Work Place Organization - 5S
Visual Factory - Accountability, Pace Boards
TPM
Quick Change - SMED
Lean Assessment
Process Certification

© Visteon Corporation GB-Mod #1 Rev 3.6 10/03 3

What is Lean? Individual Lean Components
Creating the Lean Production System

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Part Name: Appliqué
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Part Name: Appliqué Line - Location
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Box Capacity (inches)
Part Name: Appliqué
Boxes Required 1 Box size 12”x15”x12
Supplier: 1000 Serigraph
Box Capacity (inches)

Boxes Required 1 Box size 12”x15”x12

Box Capacity 1000 (inches)

* PLAN FOR EVERY PART (PFEP)

© Visteon Corporation GB-Mod #1 Rev 3.6 10/03 4

 Inventory Profile of the
UK Automotive Supply Chain
First Tier Inbound Vehicle Outbound Distribution
100 Suppliers Logistics Manufacturers Logistics & Retail
90 Max
80 Average
Days of Inventory

70 Min
60

50

40

30

20

10

Customer
Outbound
Components
Pre-Assembly

Marketplace
Loading &
On-site Part
Assembly WIP

Despatch
In-house built

Production WIP
Bought-out Parts
Raw Material

Inbound Transit

Transit
Finished

(VM)
Parts

Vehicle
WIP

Source: Holweg (2002)

© Visteon Corporation GB-Mod #1 Rev 3.6 10/03 5