Site news 26.09.2014
September 26, 2014, Rybinsk. - In September as part of Lean manufacturing deployment within the company, NPO Saturn launched its first “Process factory”. This new business simulation will allow to provide hands-on training to the use of Lean tools and build formidable Lean competences over a short period of time.
In the course of a game-based training dubbed “Fuel pump assembly line’ the company employees sought to improve such key factors as productivity, systemacy of approaches, level of awareness and team spirit. The game is played in three rounds emulating the production stages, meetings, trainings and transformations. The ultimate goal is to be able to assemble 20 fuel pumps during the controlled practical phase of each round staying within 20 minutes and reach the set performance and customer satisfaction indicators. The participants receive their roles - a machine tool operator, an inspector, a logistics engineer, a planning engineer, a process engineer, a rate setter, a production area supervisor or an improvement engineer. They are also given appropriate uniform and receive the necessary instructions. The production processes are the same as those in real life (parts and subassemblies, tools, machine tools, personal protection equipment and instructions); however the production management system is not the conventional one but the one which is based on the Shop Floor Management standard.
The “Process factory” has already been passed by the company’s production director, chief financial officer, senior management of the economic and financial direction, chief engineer and their deputies as well as the heads of the production competence centers.
What makes the Lean laboratory so unique is that a participant is “submerged” into the process more fully and more quickly since a simulation allows to reproduce more realistically the real processes ongoing in the company.
Ilya Pautov, deputy NPO Saturn CEO, production system development noted that “the main objective of Lean manufacturing is to reduce costs and waste. As a result of the Lean manufacturing deployment, productivity is increased 2-3 times. A game-based Lean training is one of the most effective ways to teach people what Lean manufacturing is and what it does. The utility of such training is in the fact that a person acquires hands-on Lean application skills and a real understanding of the effectiveness of using Lean tools in the conditions which are very close to reality, which in turn leads to a simplification and acceleration of putting the acquired knowledge and skills to practical use in a real production set-up.”
The implementation of Lean manufacturing in the companies integrated in United Engine Corporation is one of UEC’s development strategy items. NPO Saturn started its Lean journey back in October 2009 following the initiative and under direct leadership of the company chief executive officer Ilya Fedorov. To date Saturn has conducted 11 waves of transformations having realized 85 Lean projects; the company has also elaborated and officialized its Lean manufacturing development policy until 2020; a process of preparing the future change leaders - black and green belts - is launched in the company.
Application of the state-of-the-art management techniques is dictated by the need to equilibrate the company’s internal and external resources in the conditions of a drastic increase in production demand to be able to ensure on-time delivery and satisfy the company’s customers.
The NPO Saturn Research and Production Association (OJSC) is an engine-building company specialized in the design and development, production and after-market support of gas turbine engines for military and civil aviation, naval ships and power-generating plants and gas-pumping units. The association is part of the All-Russian public organization The Union of Russian mechanical engineers whereby the regional branch is headed by I. N. Fedorov, NPO Saturn CEO.
NPO Saturn is part of United Engine Corporation (OJSC) and acts as the leader of the Civil Engines Division, a business unit of UEC founded on 09.10.2012 as a result of integration of the following companies: NPO Saturn (OJSC), Aviadvigatel (OJSC), PMZ (OJSC), Metallist-PM (CJSC), Energetik-PM (OJSC), REMOS-PM (CJSC), Motoservis-PM (CJSC) and Zheleznodorozhnik-PM (CJSC).
United Engine Corporation (OJSC) is a subsidiary of the OBORONPROM UIC (OJSC). The UEC structure integrates over 85% of Russia’s leading companies specialized in the design and development, serial production and after-market support of gas turbine machinery as well as the key enterprises - the industry’s integral players. One of UEC’s prioritized fields of activity is the implementation of comprehensive programs of development of the companies in the industry by introducing new technologies meeting the world-class standards.
The OBORONPROM United Industrial Corporation (OJSC) is a multi-field machine-building group created in 2002. It is part of Rostec. The main fields of activity are helicopter building (the Russian Helicopters holding), engine building (the UEC holding) and other assets.
The Rostekhnologii State Corporation (Rostec) is a Russian corporation established in 2007 in order to facilitate the development, manufacturing and export of high-technology industrial products of military and civil purposes. Today it comprises over 663 companies, which form 9 military-industrial and 5 civil industry holdings. Rostec’s subsidiaries are located in 60 regions of Russia and supply their products to over 70 countries worldwide. In 2013 revenues of the Corporation amounted to RUB 1.04 trillion, net profits were RUB 40 billion and total taxation exceeded RUB 138 billion.