1. Lean@Hilti The way to operational excellence Mr Patrick O’Connell Kostas Kefalakis Hilti Corporation

2. Agenda Introductions & Expectations from the group
Why is fundamental to our strategy
History of
Global & Local Lean structure
How we spread

3. Lean is 50% about Tools & 50% about Mindset
Both are required to reach
operational excellence
It takes Tools and Systems
to create results and
business impact
It takes a Culture of Excellence
(Mindset & Behaviors)
to sustain results

4. Why Lean@Hilti & Link to our strategy
The elimination of waste and continuous improvement makes us
Faster…in our processes
Better…in the quality of our products and services
More cost effective…in the way we do business

5. Eliminate non-value-adding activities
Eliminating waste = Reduced lead time
Eliminate non-value-adding activities
From the customer
Value stream
To the customer
Reduce lead time

6. Examples of Wastes Inventory Motion Waiting
Transport/information transfer
Unused potential
Over processing/unsuitable methods
Defects
Over information/production

7. History of Lean @ Hilti Lean@Hilti next level 2016+ 2015
Value stream thinking
2014
Lean in R&D
2013
Lean Assessment
2012
Lighthouse projects in different areas
2011
initiated
2010
Cookbook, standards, methods
2009
Start of Lean journey in Manufacturing
Various methods…

8. Local Lean is vital to support the Lean journey
Line organization:
Local/ Regional LEAN organization:
Global LEAN organization:
Region Head/ Plant Manager
Head of LEAN Global SC
Warehouse/ Unit Manager
LEAN Manager
Local (60 – 100%)
LEAN Manager
Global SC
Coach
Jr. LEAN Manager
Local (100%)
Optional position, mandatory only at certain conditions
Global LEAN community
Change Agents within workforce (>10%)
LEAN Exchange and best-practice sharing
Solid line
(direct report)
Dotted line
(Functional)
Example from Supply Chain

9. How we spread Lean@Hilti: 4 Main Focus areas
Trainings & Workshops
Support Projects
Lean Assessment
Gemba coaching

10. Management Kick-off & Buy-in
Experience visits
Champions and unit Manager Lean Basic training
Vision workshop
Lean road map and target per function

11. Foundation of CI: Speedy Quality Circle
Method to rapidly tackle small problems and improvement ideas
Foundation for creating a bottom-up inclusive culture
Embeds mindset of PDCA, problem definition, 5-why etc

12. Kaizen Workshop – “our bread & butter”
3-5 day event that uses a cross-functional team empowered to solve problems and drive improvements in a rapid manner on the shop floor
Key Roles: Sponsor, Lead, Facilitator, Core team, Supporting team
Example of Kaizen Workshop:

13. Kaizen Workshop Example – Manufacturing
Topic: Transport Mgmt. Workshop
Scope: Machine disturbance & Working space
Team: 6 persons + Global lean facilitator
Days: 3 days
Impact: +20% pieces/shift | -50% walking

14. Kaizen Workshop Example – Transportation
Topic: North America Transport Management
Scope: Reorganize Transport routes
Team: 10 persons + Global lean facilitator
Days: 4 days
Impact: $

15. Kaizen Workshop Example – R&D
Topic: Shorten Development Loops
Scope: Dev.  Prod.  Assy  Test
Team: 8 persons + Global lean facilitator
Days: 2.5 days
Impact: -30% in development time
Before
After

16. Support for Projects - Value Stream Projects
1-4 month project that uses a cross-functional team empowered to improve the entire value chain of a product from customer to supplier
Key Steps: As-is analysis  Target state  Solutions  Follow-up
Example: Batteries VSP – 7 workshops over 4 months with a team of 6
Results: $500,000 savings

17. Gemba Coaching Lean tool used to;
Drive standardisation and sustainability
Bring leaders closer to the ‘Gemba’ and to the team
Drives continuous improvement
Completed daily on different topics and all levels of the organisation
Findings worked through the continuous improvement cycle

18. Lean Assessment
11-categories assessed over 2 days on-site global & local leadership to evaluate the lean maturity of a site to define next steps
Maturity assessment in order to guide the site to the next level of Lean

19. Why Lean@Hilti & Link to our strategy
The elimination of waste and continuous improvement makes us
Faster…in our processes
Better…in the quality of our products and services
More cost effective…in the way we do business