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Lean In Vestas Nacelles Italy The Lean Manufacturing Journey

Francesco Velluto

- VP Divisione Vestas Nacelles A/S

- AD Vestas Nacelles Italia – Taranto

- 49 anni, sposato, una figlia di 12 anni

- nel settore eolico dal 1990

- in Vestas dal 1998

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E siamo più di 20.000 dipendenti che credono nel vento

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Elisa Nicoletti

- PEX Manager

- 34 anni

- in Vestas dal 2008

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Content

1.Vestas: introduction to the company and its business

2.Vestas in Taranto

3.Vestas Journey through Lean Manufacturing

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Reaching our vision

Wind is…

Reducing green house gas emissions and climate change

Creating jobs and investment

Building energy security

Reducing dependence on fossil fuels

CO2

Introduction to the company

and its business

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We have installed close to 49,000 turbines in 73 countries worldwide spanning six continents 49,000

We monitor almost 25,000 turbines, or 43,000 MW, day and night and the data is used for efficient service planning and pre-emptive maintenance

25,000

We employ around 18,000 people worldwide from 85 nationalities and have more than 30 years of experience with wind energy

18,000

Vestas in brief

*Source: BTM Consult, 2012

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We are a truly global organisation

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55 GW amounts to 49,000 turbines, which generate enough clean energy to power over 19 million European households.

Vestas has installed just over one out of every five wind turbine MWs installed around the globe * *

Vestas has installed 55 GW of wind energy 65% more installed capacity than our closest competitor*

*Source: BTM Consult, 2012. * * Source 238 GW (at the end of 2011), according to the Global Wind Energy Council (GWEC).

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Our vision

Wind is…

Reducing green house gas emissions and climate change

On par with oil and gas

Building energy security

Reducing dependence on fossil fuels

CO2

Bringing wind on par with oil and gas Our aspiration, stated through our vision, is a society where at least 20% of the global

electricity supply is provided by wind.

Industry leading track record in turbine development

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Vestas’ track record of turbine evolution over 30 years is unmatched in the wind industry

8.000

… backed by performance guarantees

Superior service and certainty through:

the right PEOPLE, supported by

the right INTELLIGENCE, using

the right OPERATIONS AND MAINTENANCE plan,

the right INFRASTRUCTURE, maintaining

a strong PARTNERSHIP

Operation & Optimisation: Active Output Management Our commitment to you

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Safety comes first at Vestas

33% annual reduction of industrial injuries at

Vestas since 2006.

In 2012 there was record low 2.8 injuries per one

million working hours

In 2015, the target is 0.5 injuries per one million

working hours

Incidence of industrial injuries (per 1 million working hours)

25,3

20,8

15,6

8,1

5,0 3,2 2,8

2006 2007 2008 2009 2010 2011 2012

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Servicing throughout the wind project value chain Vestas is dedicated to working in partnership with customers to deliver the lowest cost of energy and maximum return on investment in wind energy.

Financing. Siting. Grid requirements. Local policy and regulations. Customers need to consider a wide range of crucial factors when they invest in a wind power plant. And not just at the planning stage, but for the whole lifecycle of the project.

Project planning

When customers choose a wind power supplier, they need a business partner with a track record of innovation, commitment and success of delivering wind power plants. A partner like Vestas.

Procurement and construction Operation and optimisation

Building a wind power plant is one thing. Operating it at optimum efficiency is another. Whether it is managing and maintaining the turbines, training customers to operate them..

Edit ”purple” bar to cover full cycle

Vestas in Taranto

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Vestas Nacelles Italia

Vestas Blades Italia

Vestas Italia

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Servicing throughout the wind project value chain Vestas is dedicated to working in partnership with customers to deliver the lowest cost of energy and maximum return on investment in wind energy.

Financing. Siting. Grid requirements. Local policy and regulations. Customers need to consider a wide range of crucial factors when they invest in a wind power plant. And not just at the planning stage, but for the whole lifecycle of the project.

Project planning

When customers choose a wind power supplier, they need a business partner with a track record of innovation, commitment and success of delivering wind power plants. A partner like Vestas.

Procurement and construction Operation and optimisation

Building a wind power plant is one thing. Operating it at optimum efficiency is another. Whether it is managing and maintaining the turbines, training customers to operate them..

Edit ”purple” bar to cover full cycle

«Vestas journey through Lean Manufacturing»

La trasformazione Lean in Vestas

Le criticità e le soluzioni

I benefici per gli stakeholder

Lessons Learned

Introduction of new tools, systems, organizations in

order to improve the company’s competitive position

in the market

1. Product Innovation

New Products (Technology R&D)

2. Process Innovation

Assemble at lower costs

Lean Manufacturing

Principio della Riduzione dei Costi: PROFITTO = PREZZO DI VENDITA - COSTO

Approccio

Lean

Approccio

Tradizionale

Profit Profit

Profit

Costo

di

Prod

Costo

di

Prod

Costo

di

Prod Prezzo

di

Vendita

Prezzo

di

Vendita

VENDITE

Profit Profit

Profit

Costo

di

Prod Costo

di

Prod

Costo

di

Prod

Prezzo

di

Vendita

Principio del Valore Aggiunto: PREZZO DI VENDITA = COSTO + PROFITTO

Spreco

VENDITE

Prezzo

di

Vendita

Cosa vuol dire “Eliminare gli Sprechi”

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STABILITY

JIT

JIDOKA

Continuous

Improvement

Culture

Pull

Takt

Flow

QbD

Pokayoke 5S

Visual Management

Std. Work

The Lean Turbine

Taranto Plant - 2007

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Make to Stock

Unbalanced Line

High Lead Time

High DoS

Big Warehouse

High WIP

High FG stock

High transportation

High motion

Supplier Factory

Customer

FG

Forecast Demand

June 2007 - Taranto Factory – Assembly line Layout

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Warehouse

Warehouse

Assembly Line

Assembly Line

Warehouse

Warehouse

“The Lean Journey in the Supply Chain”

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Current State

Specify Value

Identify Value

Streams

Create Flow

Leverage Pull

Seek Perfection

Lean Supply Chain

5 Principles of Lean

Value Stream Mapping

• Preworkshop

• Current State

• Future State

Spread new culture

Inventory Hides Problems

Raw Material Finished Goods

Company

Line imbalance

Poor communication

Poor scheduling

Quality Problems

Supplier delivery

problems

Poor scheduling

Poor 5S

Long set up times

September 2008 - Taranto Factory – New Assembly Line Layout

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Warehouse

Warehouse

Assembly Line

Assembly Line

Warehouse

Assembly Line

Warehouse

Lean in Vestas

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Percorso Lean in Vestas Nacelles Italia

Value Stream Mapping

Taktime

Da Make to Stock a Make to Order: PULL

100% personale formato

Bilanciamento della linea

50% riduzione Lead Time

91,5% Riduzione DoS

Supplier Factory

Customer

FG

FG

Forecast Demand

Continuous improvement: Striving for Perfection

Continuous improvement journey.

Produce exactly what the client wants, when they

want it, and at the lowest cost.

27 | Vestas sustainability department

Thanks for your attention