cme kaizen conference 2014 – leading lean transformation...
TRANSCRIPT
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
LEADING LEAN
TRANSFORMATION
Tony Kerwin, P.Eng. Chief Operating Officer
Acrylon Plastics Inc. Winnipeg, Manitoba, Canada
February 20, 2014
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Acrylon Overview
Your Ideas, Our
Solutions
• 6 Facilities – SK, MB, Minnesota – HQ in Winnipeg, MB
• Over 300 people • ISO9001 Registered since 2002 • 45+ years in the plastics business • Over 30 years design engineering
experience • Multiple quality test labs • In-house jig/fixture
manufacturing • Complex assembly capability
• Color mixing capability • Data pack in-mold heat
monitoring • Extrusion Die making capability • Gel test capability • 23 rotomolding machines
– Up to 4500 pound capacity
• 5 vacuum forming machines • 8 single screw extruders • 16 twin screw extruders • 9 CNC trimming machines
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Passionate People Forming Creative Solutions We will: Partner with selected leading Customers and Suppliers, earning their long-term loyalty.
Effectively deploy a safety culture and continuous improvement.
Pledge to our passionate team members a consistent, transparent and knowledgeable workplace.
Encourage a culture of engagement and respect through active communication.
We will act ethically at all times.
We will conduct ourselves responsibly within our community
Maximize long-term Customer and Shareholder value.
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Core Values
We trust our coworkers and treat each other with mutual respect and honesty.
We work in an open, transparent, thoughtful culture.
We take pride in our diversity.
We are passionate about our growth opportunities and participating in the success of all of our stakeholders.
We act ethically at all times. We actively support our local communities and conduct ourselves responsibly within
them.
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Henshaw Award for Corporate Leadership in
Safety
IAPA PRESIDENT’S SAFETY AWARD
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
• Ensure ALL Actions are Legal, Ethical & Moral • Actively Participate and Communicate Openly • Sign Your Work With Personal Pride • Focus Passionately on Waste Elimination • Aim for Excellence & Perfection • Treat Others With Dignity & Respect • Strive to Make a Difference Every Day • Lead With Your Heart as Well as Your Head • Follow Through on Your Commitments • Always Spell Customer with a Capital “C” • Be committed to the betterment of the team • Play to Win Every Day – Don’t Compromise
People Expectations
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
• Deal With Facts not Opinions • Maintain Confidentiality • Do Not Engage in Rumour Mills • Be Professional in All Activities • Be a Role Model for All Employees • Once a Decision has been made, Support it 100% • Be Responsible and Accountable for Your Actions • Engage in Proactive Performance Management • Be a Team Player • Support the Other Leaders – Do Not Criticize
Leadership Expectations
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Pseudo Team
High Performing Team
perf
orm
ance
team effectiveness
Work Group
Potential Team
Real Team
Source: Katzenbach and Smith - The Wisdom of Teams
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
FMEA SMED
KANBAN
EPEI
TPM
FLOW
POINT OF USE
5S POKA -YOKE STD
WORK VSM DMAIC
SPC
5 WHY
KAIZEN
DOE
FMEA
TWI
V of C Cp
CpK
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Customers (The Designer)
External Focus
C A P A B I L I T I E S
Inventory
Lead Time
Quality
Cost
Service
Product Development
Sustainable
P R O C E S S
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
EHS
Quality
Throughput Profit
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
THINK SMALL. Small changes rather than big changes.
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
改 ("to change") + 善 ("good")
KAIZEN
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Kaizen Activity
0
50
100
150
200
250
300
350
400
450
Octobe
r
Novem
ber
Decem
ber
Janu
ary
Februa
ryMarc
hApri
lMay
June Ju
ly
Augus
t
Septem
ber
YTD Target
YTD Actual
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Kaizen Activity
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Total Inventory Alumicor
23%+ improvement
INVENTORY
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Manufacturing Lead Time
0
10
20
30
40
50
60
70
80
01-J
an-0
201
-Mar
-02
01-M
ay-0
201
-Jul
-02
01-S
ep-0
201
-Nov
-02
01-J
an-0
301
-Mar
-03
01-M
ay-0
301
-Jul
-03
01-S
ep-0
301
-Nov
-03
01-J
an-0
401
-Mar
-04
01-M
ay-0
401
-Jul
-04
01-S
ep-0
401
-Nov
-04
01-J
an-0
501
-Mar
-05
01-M
ay-0
501
-Jul
-05
01-S
ep-0
501
-Nov
-05
01-J
an-0
601
-Mar
-06
5/1/
2006
7/1/
2006
01-S
ep-0
601
-Nov
-06
01-J
an-0
7
82% Reduction
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
ON TIME DELIVERY PERFORMANCE
0%10%20%30%40%50%60%70%80%90%
100%
1996 1997 1998 1999 2000 2001 2002 2003
TARGET
REDEFINITION OF OTD
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
INVENTORY TURNS
0
5
10
15
20
25
30
May-00
Jul-0
0
Sep-00
Nov-00
Jan-01
Mar-01
May-01
Jul-0
1
Sep-01
Nov-01
Jan-02
Mar-02
May-02
Jul-0
2
Sep-02
Nov-02
Jan-03
Mar-03
May-03
Jul-0
3
TARGET
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
QUOTE TURNAROUND PERFORMANCE
0
5
10
15
20
25
1999 AVG
2000 AVG
01/0102/01
03/0104/01
05/0106/01
07/0108/01
09/0110/01
11/0112/01
01/0202/02
03/0204/02
05/0206/02
07/0208/02
09/0210/02
11/0212/02
01/0302/03
03/0304/03
05/0306/03
07/0308/03
DA
YS
TARGET
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
52% reduction in internal defects to 22 PPM
100% reduction in Customer rejects to 0 PPM
Reduced Class A supplier lead time by 30%
Improved Asset Turnover by 10%
Reduced cycle time by 76%
Reduced order-to-delivery lead-time by 36.8%
Reduced Raw Material Inventory by 25%
Reduced WIP by 80%
50% Improvement in First-Time-Yield
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
Your Ideas, Our Solutions.
CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION
© 2014 Tony Kerwin
LEADING LEAN
TRANSFORMATION
Tony Kerwin, P.Eng. Chief Operating Officer
Acrylon Plastics Inc. Winnipeg, Manitoba, Canada
February 20, 2014