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The 4th corporate workshop on transforming production systems: winning the Perm Engine Company problem

UEC held its fourth corporate workshop on transforming production systems (Lean workshop) on June 26-28, 2013. The event was organized by UEC’s department for the development of production systems, together with the OBORONPROM Corporate University and Perm Engine Company (Perm).

Workshop participants included employees from United Engine Corporation companies and Russian Helicopters companies: Ufa Engine Industrial Association, Klimov, Perm Engine Company, the Chernyshev Moscow Engine Company, NPO Saturn, Salyut Gas Turbines, MOTOR, YZGA, Saturn Gas Turbines, STAR, Aviadvigatel, Kuznetsov, Kazan Helicopter Factory, Rostvertol, and Progress.

The workshop to transform production systems is practical training on Lean technology, based on attracting participants to solving real problems within the companies. Running the workshop is aimed at creating a single team for the corporation, aimed at transitioning work to ‘lean schemes’. Each participant has a unique opportunity to test himself in ‘battle’.

The management of Perm Engine Company selected six problem ‘cases’ for the workshop:

1. Ensuring rhythmic delivery of ceramic molds for making casts

2. Optimizing the production process of casting blades

3. Increasing the throughput capacity of the nozzle assembly process

4. Optimizing quality control operations on assembly line 31

5. Increasing the throughput capacity of making examples in the central laboratory for managing technical oversight

6. Increasing the throughput capacity of assembly of nodes at the assembly and testing facility

Over the course of two days, six groups of 8-9 people each analyzed the problems and looked for the root causes, applying Lean tools. On the third day, the groups presented their solutions to experts — a real road map for the project (including, where possible, performing simple transformations in place).

The experts were heads of PMZ and members of the Lean Technology Problem Committee No. 8A under the Russian Ministry of Industry and Trade. The expert group was headed by Valentin Sizikov, the Director of the Department of Production Systems Development at UAC. The experts included heads of divisions on the development of production systems from Sukhoi, Russian Helicopters, Irkut Corporation, UEC, and others. The experts evaluated the workability of the solution plans and client satisfaction with the proposed solutions.

According to the clients and experts, the best solutions came from Group No. 4 led by Alexey Tormyshev (manager at Klimov). The project ‘Optimizing quality control operations on assembly line 31’ was named Best Project. Group participants (Sergei Samoylov — Chernyshev, Ildar Baishev — Salyut, Olga Baranova — UZGA, Alexander Kushko — Aviadvigatel, Ilya Muravyev — Saturn Gas Turbines, Vera Koneva — UMPO, Marat Almakaev — Motor, Svetlana Zyryanova — PMZ) were awarded certificates from the corporate university and given gifts.

Certificates for ‘Leader in Transforming Production Systems’ were awarded to three participants:

1. Yevgeny Vasilyev — leading specialist in the Lean technology department at Saturn Gas Turbines

2. Sofiya Glinkovskaya — manager at Chernyshev Moscow Engine Building Company

3. Tatyana Roslova — leading specialist at NPO Saturn

The system to pick out and evaluate leaders has been in place since March 2012. To date, leadership certificates have been awarded to 22 employees of DPS services at UEC companies. The results of the system to identify leaders can be described by the following facts: more than 50 % of the leaders have been promoted one or two levels up the career ladder in just one year.

In the next workshops, leaders will act as mentors in group work projects. It is worth noting that the leader of the winning team, Alexey Tormyshev, won a certificate as ‘Leader in transforming production systems’ in March 2012.

United Engine Corporation is a wholly-owned subsidiary of OBORONPROM. More than 85 % of the leading companies specializing in the development, mass production, and aftersales servicing of gas turbine technology are integrated into UEC, as well as key companies in other selected fields. One of UEC’s priority directions is implementing comprehensive programs for developing companies by implementing new technologies that meet international standards.

OBORONPROM is a multi-faceted machine-building group of companies built in 2002. It is part of the Russian Technologies group of companies. Its primary activities include helicopter building (Russian Helicopters) engine-building (UEC), and other assets.

Russian Technologies is a Russian corporation founded in 2007 to facilitate development, production, and export of high-tech industrial products for civil and military applications. Altogether, the Corporation encompasses 663 organizations . The corporation includes 17 holdings, 12 of which are in the military-industrial complex, and five of which are in civilian industry. The Corporation works in 60 constituent entities of the Russian Federation and supplies products to more than 70 countries around the world. It employs more than 900,000 people, or about 2 % of Russian labour force. Its 2011 net profit was 45.6 billion rubles, and it paid a total of 100 billion rubles in taxes at all levels.