Lean Implementation

At Siemens Kalwa
Plant
CASE ANALYSIS: LEAN SYSTEM
DHARMANSHU BINANI
SHAKTI SHIWAM
 A brief about Siemens

The Beginning: 10 employees, 180 SQ Meter workspace May 1955

2009- 55% subsidiary of Siemens AG Germany
Factories - Kalwa, Nasik, Calcutta, Aurangabad and Goa
4000 Employees
11 Sales Office
23 Representatives
300 dealers
Second largest factory outside Germany
Four major divisions: Industry, Energy, Healthcare and
Consumer products
Kalwa : Sole manufacture of Medium Voltage,
The Current cycle at
plant
 Implementation Pattern
for Lean
The overall step in Lean Implementation were as follows:
 Implementation Pattern
for Lean
The basic implementation pattern can be divided in
terms of following
 Effectiveness in
achieving lean
implementation
The following 5 major outcomes can determine the
effectiveness of Lean Implementation
Effectiveness in
achieving lean
implementation
 Resistance Faced
Communication of Goal again and again
The
following
Using T-shirts to show the importance of the LEAN
were the
resistanc Identification of the exact point of error in meeting & making employee accountable
e faced
Automation was to be adopted to reduce human interference

Re-shuffling the team as and when required

Documentation and SAP based entries to have Co-ordination between departments

Changes in SAP database and design to handle error in design drawing

Lean a part of Individual and Team appraisal for mindset change

Khandekar making employees aware about their faults & linked result of organizational
losses
Bonus of worker related to the productivity

The Union and there united resistance via the same

Introduction of new designed product in the same line and disruption in existing process
Managing Resistance
 Activities so that the changes are not
reversed
People Process
Implement on other processes
Engrave Lean as culture
too

Further Training and

Involve full factory
Development

KAIZEN to existing
Optimize the Process
implementation

Stakeholder
Productivity linked Compensation Use of standardized product

Others
s
Synchronize production Continuous Monitoring

Help Vendors to implement

Documentation and Reporting
LEAN

Certification and Appraisal Auditing of the implementation

Long term contracts Further Brainstorming

Thank You