Manufacturing Excellence Awards - German
y
The MX Awards were established in Germany in 2004 by the IMechE working in conjunction with the Technical University of Berlin and the MX Germany sponsors including the Financial Times, Siemens AG, SAP, Renishaw, Thiel and Gildemeister.
MX Germany follows closely the successful structure established in the UK. Companies entering are required to complete the Self Assessment Audit, which has been translated into German and modified to suit the local conditions. The companies that come through the first round then receive an onsite visit and from this a list of finalists is drawn up. Every company that enters receives a free Benchmark Report.
Finalists then make presentations highlighting how they have achieved their success. At the end of the presentations the Awards Ceremony is held.
For more information on MX Germany visit: www.mx-award.de
2007 WINNERS
Overall Winner - Daimler AG Mercedes Benz, Werk Untertürkheim
Customer Focus - Siemens Messgerätewerk Berlin
Product Innovation - CeramTec AG
Process Innovation - Kautex Textron GmbH
Best SME - Von Ardenne Anlagentechnik GmbH
2006 WINNERS
Overall Winner - Takata-Petri (Sachsen) GmbH
This is the German subsidiary of the Japanese Group and is a leading manufacturer of integrated air-bag systems for passenger vehicles, supplying virtually every European motor vehicle manufacturer. The initial project involved building a new plant on a green field site in eastern Germany and recruiting and then training an entirely new workforce (currently around 400 employees). The operation has achieved quite extraordinary quality and productivity standards, and produces daily some 22,000 units (which includes steering wheels, airbags, gas generators, sensors and electronics).
Process Innovation - DaimlerChrysler AG Untertürkheim
The operation with 700 employees and an annual budget of Euro 60 million is responsible solely for ensuring the maintenance and optimal functioning of all plant and machinery in the engine plants, representing an investment of a staggering Euro 1.8 billion. Impressive new initiatives have been introduced using condition monitoring and the concept of total cost of ownership to achieve maximum quality, reliability and performance. The huge volume of data generated from the condition monitoring is processed and delivered in real time to the suppliers of all of the major machine tools in operation.
Product Innovation - Lange Uhren GmbH Glashütte
This is one of the most remarkable stories associated with MX. Lange, which for two centuries was a leading manufacturer of the highest quality watches had the plant flattened on the very last day of the Second World War. They struggled to re-establish operations, but in 1948 the business was confiscated by the East German Government and the owner, Herr Lange, was sent to a uranium mine. He escaped, went to Switzerland and then returned to Glashütte immediately after re-unification to find literally nothing remaining. For four years he trained 17 people and in parallel designed a revolutionary new range of watches, which were launched in 1994. The product innovation continues and the company now employs over 400 with a waiting list for its products of 18 months. One of the Lange watches produced in 1994 has recently sold at auction in New York for over half a million dollars US.
Customer Focus - Rational AG
The company manufacturers advanced computer controlled cooking centers that provide boiling, baking, roasting & grilling facilities in a single appliance for professional kitchens. It has an operating revenue of Euros 300 million and a market share world wide of over 50% including a major presence in both the USA and China. It is highly innovative with 230 patents and achieves consistently an extraordinary EBIT of over 25%. Perhaps the most distinguishing feature is that it employs an international sales force of over 100, all of whom are master chefs.
Best SME - Helbako GmbH
A highly successful privately owned company that designs and manufactures electronic sensors and drives for the automobile industry. Products split into three main categories: safety and security, engine management and body work such as sophisticated controls for folding roofs. They manufacture the elevator for the Emily Mascot on every Rolls Royce (it automatically retracts into the bonnet when parked). Investment in the latest production machines and a highly motivated workforce are major attributes – the “ Spinner Club” to which all employees belong has resulted in no less than 80 radical product innovations.
2005 WINNERS
Overall Winner - MAN Trucks Salzgitter
In the highly competitive international heavy truck market, this company has achieved extraordinary success with productivity increases of over 30% realised in the last two years. This is a reflection of flexible working practices allied to a huge investment in the most productive plant and equipment. Some 97 different basic truck types are manufactured with literally millions of variants, and this demands very flexible and responsive processes. All of the current 14,000 units per annum are manufactured to order with no finished stock. For relatively standard types, delivery is 14 days from receipt of order.
Product Innovation - Siemens Automation & Drives
With more than 2,200 employees, this company designs and manufactures machines for electronic component placement and assembly. The latest machines can select – orientate – and place up to 80,000 components per hour to extreme levels of accuracy. It has over 13,000 machines in operation with 1,600 customers worldwide all linked to provide downloaded performance data in real time. Some 46% of production is sold to countries in Asia.
Customer Focus - Lufthansa Technik
This is an independent division and profit centre of Lufthansa and is responsible for the maintenance and overhaul of not only the Lufthansa fleet but also the aeroplanes of many other leading airlines – including the low cost airlines such as EasyJet. It undertakes complete engine overhauls and has developed a highly advanced method of regrinding turbine blades. The wear on a blade varies and thus the dimensions are first automatically gauged, an optimum new profile calculated using advanced software and this data is then automatically fed to the very sophisticated grinding machines. It is claimed that the performance of the re-ground blade often exceeds that of the original. There is a very clear emphasis on assessing customer requirements and then satisfying these requirements.
Process Innovation - Draeger Safety
This company manufactures a range of products for identifying noxious gases, gas masks and protective clothing, and diving equipment used for both military and civil purposes. Around 77% of total production is exported. Radical improvements have been achieved in a range of manufacturing processes that has led to significant rises in productivity and customer satisfaction. There is a strong emphasis on in-house design of purpose built machines and new manufacturing technologies that it is claimed result in competitive advantage in world markets. Average growth in sales since 2000 is over 8% with more than commensurate increases in profitability.
Best IT Application - VS Moebel
Most German schoolchildren know this company’s products intimately. VS Moebel is the leading manufacturer of schools desks and chairs, together with quality office furniture. A huge product range and severe competition in export markets led to a fundamental review of processes and a decision to bring about change through the highly skilled introduction of advanced manufacturing systems that has led to major reductions in lead time, and increases in productivity. The USA is a major export market for their products.
Best SME - Drilbox
This Award, presented by the IMechE, went to Drilbox. The product of this company could not be more basic – literally the metal boxes for drill bits. They claim to have over 70% world market share. How can such a product be manufactured successfully in high cost Germany and sold in Japan, China and Taiwan and to nearly every drill manufacturer in the USA? There is a lot of pragmatic, relatively low level engineering – but the real answer lies with the motivation of the employees who are all effectively shareholders in the business and inspired by a charismatic owner.
The MX Germany trophy