Read this article about Flex, Finalist in the Best Achievement in Operational Excellence to deliver Business Transformation, selected by the independent judging panel, for the 2021 Digital Transformation & Operational Excellence Industry Awards program.
Flex Value Stream 4.0 Transformation
Flex is the Sketch-to-Scale® solutions provider that designs and builds intelligent products globally. With approximately 200,000 employees across 30 countries, providing innovative design, engineering, manufacturing, real-time supply chain insight and logistics services to companies of all sizes across multiple industries and markets.
Flex Sárvár Hungary manufactures a different variety of Automotive products. One of the highest runner products is a Slim Display Module.
The customer annual price reduction created huge cost pressure that combined with the European labor shortage triggered an improvement strategy along our complete Value Stream. We applied Hoshin-Kanri & Value Stream Map methodology to align & prioritize resources to the targets of the site and deployed and closed 21 Kaizens to Business Needs.
A key element of our strategy started in 2018 with the transformation from a labor dependence process to a fully automated process. The goal was to transform the subjective cosmetic inspection done by operators to a repeatable decision made by camera systems, internal material transportation made by material handlers to mobile robots all assembly operations that allow us to mitigate the current increasing labor shortage in Europe. During 2018 our robot density was 95 robots per thousand employees, and this has grown in 2021 to 1400 robots per thousand employees.
The second element was focused on the reduction of process scrap on plastic parts on April 2018 our level was 36,4% in the most complex plastic part. This was consuming a major part of our profit and creating bigger batch sizes to afford the high level of scrap and increasing the WIP between painting and assembly process.
Three of Kaizens t were recognized as Global Industry 4.0 Best Practice of the company and shared along with other flex sites. This includes plastic molding touchless cells integrated with mobile autonomous robots and a unique machine vision system for cosmetic inspection of painted high gloss surfaces.
The improvement was nominated to be part of the Flex Global Lean Six Sigma Competition Grand Final 2021 where the best 12 projects worldwide are presented.
People from all levels of the site were engaged, people from Other flex sites, suppliers, and Lean Experts from the customer side.
Achievements:
• Reduce Material Loss by 41%
• Increase of Inventory Turns by 34%
• Reduce Customer ppm by 61%
• Reduce Total Lead Time by 43%
• Increase Customer Satisfaction by 11,5%
• Reduce the number of product touches by 55%
• Reduce assembly Head Count by 29%
• Increase Assembly Productivity (UPPH) by 32%
• Reduce Molding Head Count by 100%
• Reduce Painting Head Count by 25%
• Reduce Molding Material Handlers by 100%
• Increase Molding OEE by 17,6%
Digital Transformation & Operational Excellence Industry Awards 2021
About the Awards
The Digital Transformation & Operational Excellence Awards have been established to showcase globally the most outstanding achievements through the application of Business Transformation, Digital Transformation, Operational Excellence & Innovation Excellence programs. Click here to view the Press Release.
The winners will be announced at the Awards Ceremony at The Digital Transformation & Operational Excellence World Awards (DTOES) on Wednesday, December 15th, 2021, from 6:30 PM at Renaissance Orlando at SeaWorld®.
The Business Transformation & Operational Excellence Awards are open to all organizations, both private and public sector, across the globe, which have implemented Business Transformation, Digital Transformation, Operational Excellence & Innovation Excellence programs to deliver outstanding business results.
The Awards will be held in conjunction with the Business Transformation & Operational Excellence World Summit, BTOES 2021 on December 15, 2021, at the Renaissance Orlando at SeaWorld®. Click to access the agenda, view the current speakers, and watch the highlights video from last year.
Speakers
Agenda
Highlight Video
BTOES.com
BTOES is the industry’s biggest and best, senior-level, cross-industry gathering of Business Transformation & Operational Excellence industry leaders and senior executives.
With over 150 speakers, over 100 sessions, 12 Keynotes, 9 Track Themes, 5 parallel tracks, 60+ track sessions, 50 roundtable discussions, 20 Interactive Workshops, 6 Thought Leader Panels, 5 Leaders Boardrooms, 5 co-located events, the Industry Awards Program, Site Visits, 20+ hours of social networking including 2 gala cocktail parties, dinners, numerous group activities, this is the ultimate event to benchmark, network and drive Operational Excellence to the next level.
Quick Links
Speakers
Agenda
BTOES Awards
There is a strong focus on Cultural Transformation, Customer Delight, Sustaining an Operational Excellence program, Need for end-to-end Business Transformation, Keeping up with new technologies/impact of digitalization and Leadership Buy-in & Understanding. We dedicated two tracks to advanced technologies, such as AI, Machine Learning, RPA, Predictive Analytics, Blockchain, Cloud infrastructure etc.
The agenda is designed to encourage active meaningful conversations through all day enhanced networking and interaction opportunities, including
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