Production
With 23 production sites and 36 personalization centers strategically positioned around the world, Gemalto is uniquely placed to respond rapidly and flexibly to our customers’ demands, and efficiently deliver the highest quality products.
Our desire to be totally customer focused across all our operations is the
driving force for change in our business. The effective management of that
change process is clearly critical to its success.With our belief that
Gemalto’s most valuable asset is our people, their implication in this process
is a fundamental concern. Emphasizing flexibility and empowerment, we are
training our people to excel in their work and motivating them to carry out the
necessary changes. In this way, and by gaining their full support, we are
effecting a step-change in the way we run our operations. To do this we have initiated a universal World Class Manufacturing program to ensure all our facilities are operating at or above “Best in Class” standards. This is expressed in a 10-point charter which proactively guides our actions at every site, and is managed through a series of key performance indicators.In summary it focuses on:
Many plants chalked up significant successes in 2006.
- Customer satisfaction as our top priority
- Management & people development providing direction and motivation
- Improvement Management as a way of life
- Workp Environment as crucial to the efficiency of our operations
- Process Control insisting on “right first time” production
- Assets Optimization and Total Productive Maintenance (TPM)
achieving high performance while eliminating variability- “Just in Time” order to delivery flow ensuring prompt supply as promised
- Security as a fundamental value-add
- Suppliers and Partners who we continuously encourage to improve
- Product and Process design as keystones to efficient, reliable manufacturing.
< In Spain, our personalization site in Madrid has implemented changes slashing 50% off its cycle time at no cost.
< In Mexico, our Cuernavaca plant responded to increasing demand in Latin America for GSM SIM cards by achieving a 57% productivity increase in its packaging activities; and our Iztapalapa facility achieved huge improvements in personalization lead time and productivity by introducing a cell concept.
< In Brazil, our Curitiba plant also implemented the cell manufacturing process to reduce a production cycle from 2 days to 3 hours.
< In Filderstadt, Germany, site a new scheme to encourage employee suggestions resulted in 80% more ideas coming forward; a new embedding process yielded 100% speed gain; and TPM has increased overall productivity by more than 20%
< In China, our Tianjin facility doubled the speed of card personalization and saved 25% of the plant’s capacity by introducing "Design for Manufacturing" methodology; while in Zuhai our Goldpac entity won the “2005-2006 Distinguished Services Award” from the Ministry of Construction for its “extraordinary performance” in quality control, embedding, application and service
< In our site in Gemenos, France, manufacturing cycle time has been reduced by 30% by implementing a Just-In-Time and Cell concept.
< In Tczew, Poland our site significantly improved its efficiency by the implementation of visual management tools.