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ePaper created 2015-05-06, 08:18:29 | version 1.38.0
59HERAEUS | ANNUAL REPORT 2014 | WORLD CLASS PRODUCTION Model of a future production Last but not least, the production planners of Heraeus developed a practical model of future production. The new UV Lamps and Systems facility at the Alzenau location is intended to act as a lighthouse and training center for lean production at Heraeus. The ensuing production landscape is in step with the idea of lean production: • Following goods receipt inspection, all raw materials are taken to a warehouse organized like a supermarket on an extremely reduced area. Fast supply to production is ensured by short distances between the warehouse and the production line. • At the end of the production chain, a similarly designed warehouse is available for the finished products. “Deliveries are made quickly from here. This is how we avoid extensive stock levels”, says Wolfgang Stang, General Manager of Heraeus Noblelight. “At the same time, it takes little administrative efforts because we do not need any external service providers for warehouse logistics.” All steps are perfectly clocked The idea of lean production is of course reflected by actual production. Everything is located at the same level: • All sequenced steps are located immediately next to one another. The fast supply of materials also creates a logis- tical axis down the assembly lines. “Accurate planning ensures that the materials on stock never exceed the amount used for production on the next day. At the same times, production is flexible enough to allow both small batches and large production quantities”, says Stang. • To match the general idea, planners integrated preven- tive maintenance in this production level. Engineers are therefore available very quickly should any machine downtime occur. • Production control is located in rooms above preventive maintenance – this elevated position lets production supervisors and managers have a plain view of produc- tion at all times. • In order not to distract the workforce from the produc- tion processes, there are only a few small and enclosed meeting areas in the production area. Locker and staff rooms are located in a separate area. This is keeping production clearly separate from the social areas. Available figures illustrate the efficiency of the approach: The total production area in Alzenau is as small as about 4,100 square meters. This is a 40% reduction compared to the previous production area in Hanau and Banbury, England. It seems hardly possible to conceive of a more compact and efficient solution for the complex production of UV technology. Securing a top position in the market environment “Production in Alzenau provides us with an ideal training site for lean production which also perfectly fits the aims and challenges of the HPS”, says Rolf Najork in summa- rizing the approach. “It is also a good example of the networking concept at the heart of our new orientation: Alzenau will become the future meeting place of produc- tion managers and employees from various locations to discuss the aims of the HPS. The HPS as implemented in Alzenau is essential for the future of our company.” ■