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Implementation of BorgWarner Production System - Case Study at DivgiWarner Private Limited
Abstract:
In the pursuit of manufacturing excellence BorgWarner, Inc., USA has utilized some key aspects of Toyota Production System and General Motors Quality System Basics tools to create a systematic framework called as Borg Warner Production System (BWPS). The goal of BWPS is to have robust manufacturing systems to deliver flawless quality products at lowest possible cost and give hassle free customer experience.
This case study covers the BorgWarner Production System implementation experience of DivgiWarner Pvt. Ltd. India, one of the BorgWarner's plant based in Pune and Sirsi, India.
The BWPS consists of 7 foundational elements and 23 tactical strategies. These seven foundational elements are
- Safety and Environment,
- Quality Systems,
- Employee Development,
- Continuous Improvement,
- Lean Manufacturing,
- Pre-Production Planning,
- Metrics and Audits
This framework delivered following benefits to the company:
- “Zero” safety incidences
- Customer PPM reduced from 675 to 122
- 100% On Time Delivery to customers
- Continual improvement - more than 300 kaizen projects implemented every year
- Overall Equipment Effectiveness increased from 41% to 82.9%
- Inventory Turn Over Ratio (ITOR) increased from 4.8 to 10.1
- Material movement in the plant reduced by 68%
This paper uses BWPS as an example to illustrate how to implement similar production systems, in order to improve manufacturing effectiveness. We also show how to set performance base lines, track continuous improvements, and communicate progress to pursue perfection.