Issue

SIX

CCCompassompassompass

Port Hope Operations

TheTheThe Summer Edition 2011

Message from the Plant Manager 1

Message from the WCM Plant Lead 1

Pillar of the Month: PM 2

WCM – Acronyms 2

What’s New Around the Plant 3

Employee Suggestion Program Update 4

Kaizen Activity 5

Innovation...Ingenuity...Community

Involvement 6

WCM Office 7

Tell us How We’re Doing 7

Face of Change 8

Welcome & Anniversaries 10

Chrysler Advantage Program 11

Mission Zero Challenge 11

Heat Stress Quiz 12

Gayle McKeen,

WCM Plant Lead

As we continue forward on our WCM journey, we are constantly being chal-

lenged to solve our problems by thinking with LOGIC, applying the right METH-

ODS and TOOLS with RIGOR at the right PACE in order to achieve lasting RESULTS. To do

this, WCM teaches us to employ the PDCA cycle (PLAN DO CHECK ACT), thus ensuring we

apply a structured approach to the improvement process.

The PDCA cycle is broken up into 4 stages. In the planning stage, it is important to make

sure that the problem and root cause of an issue is thoroughly identified and understood

using tools/techniques such as 5G, 5W+1H, 4M and 5 Why analysis. This confirms that the

actual root cause is detected and acted upon rather than just a symptom. Getting to and

eliminating root cause through the effective use of a countermeasure enables us to achieve

“MISSION ZERO” i.e. zero defects, downtime, delivery issues etc.

The second and third stages of the PDCA cycle is ‘do and check’. During the DO stage, tri-

als/experiments of potential countermeasures are performed and results are CHECKED to

determine effectiveness. The important aspect here is to ensure that the countermeasure

was/is effective and the results can be maintained over time.

The fourth stage is Act, it is during this stage that the successful results are permanently

implemented, standardized and maintained. It is also important that we expand what we

have learnt and apply in other areas

throughout the plant.

Going forward, our success will be

defined by the effort we are willing to

put forth. By applying PDCA logic rig-

orously, to aid in problem resolution,

we will be able to achieve lasting re-

sults.

WCM Thoughts

Our World Class Manufacturing audit in September is fast approaching and there is much to be done. We have many

teams working in the model areas throughout the plant. There is much improvement in the model areas and all

teams need to continue to remain focused on their tasks. Employee involvement is critical to our success. With your

ideas, thoughts, concerns and input, we can make better decisions on how we approach a problem or project for im-

provement. No one knows the production floor and all of its processes better than the people that work on it.

We have seen a lot of change in the past year or so and we will see much more change in the months and years to

come. We must continuously make change and continue to improve; otherwise the world will pass

us by. This plant will always strive to be better and to improve upon what we are currently doing

now.

Some people welcome change and others with less enthusiasm but change means to transition from

the past to the current and then the future. Our future requires change and we control our future.

OUR Mission: To be the standard by which all interior products companies de-fine themselves — globally ad-mired for our people, partner-ships, quality and innovation.

Professional Maintenance Pillar To become a World Class facility, we need to embrace change and this will be difficult as the tendency will be to revert back. By working together our transfor-mation will be successful.

Aims and Objectives of PM 1. To maximize equipment reliability and availability at an economical cost.

2. To eliminate unplanned maintenance activities. 3. To achieve zero breakdowns and pro-

cess failure losses with the coopera-tion of production people (AM) and quality people (QC).

RELIABILITY THROUGH SKILLFUL SUSTAINABILITY

Page 2

I have been given the opportuni-ty to explain the reasons why Professional Maintenance is needed. In a perfect world ma-chines would just run and never breakdown. However, all of us are aware that just doesn’t hap-pen and machines do break-down. Professional Mainte-nance, when applied correctly,

will help achieve our goal of Mission Zero. Maintaining our equipment is necessary to pre-vent breakdowns and materialize process sta-bility. As our objective is to ensure 100% relia-bility during scheduled production time, pre-ventive maintenance is essential to realizing our goal. Utilizing the Professional Mainte-nance Pillar methodology under WCM, we will enhance our maintenance program. So, how do we get there? Well, by doing our homework and this will involve a long process of gathering the right data from every machine in the plant. We need to consider that a minor breakdown is just as important as a major breakdown; addressing each and every one in the same way. This will enable us to obtain the information as to why and how a machine failed. The way in which we are going to obtain the information is through the use of the EWO (Emergency Work Order). When properly com-pleted, an EWO should identify the root cause and enable us to implement counter-measures against reoccurrence.

Moving forward we will be using the infor-mation from the EWOs to build a data re-source system to aid in analyzing the mean time between failures and the mean time to repair. This information will support us in our implementation of an economically sustain-ing prevention program.

When one door closes, another one opens; but we so often look so long and so regretfully upon the closed door, that we do not see the

ones which open for us. Alexander Graham Bell

Randy Ellis

PM Pillar Lead

Drink plenty of water in the heat

TERMS TO

KNOW

WCM Acronyms

PM: Profes-sional Mainte-nance

OEE: Overall

Equipment Effec-

tiveness

OPL: One Point

Lesson

5S: Sift, Sort,

Sweep, Stand-

ardize, Sustain

EWO: Emergen-

cy Work Order

MTTR: Mean

Time To Repair

MTBF: Mean

Time Between

Failure

WCM Vision

To have a fully engaged workforce dedicated to the principles of World Class Manufacturing, leading by example through:

Cultivating a completely safe work environment.

Meeting and exceeding customer expectations and requirements

Driving out all waste from our operation

WCM is the road map we will use to become the best Interior Component Plant in the world, most admired for our people, partnerships, quality and innovation.

Do you have any questions/concerns regarding WCM includ-

ing the suggestion program? Drop by our offices we would love

to see and hear from you. We are located on the south side of

the building just west of the Chrysler offices and east of the

payroll department or for some of you that have

been around for a while Kathy Fenton’s old of-

fice and the old injection office area.

Page 3

New logo and tagline emphasizes heritage of precision craftsmanship...

Port Hope, Ontario – Cpk Interior Products Inc. today unveiled a new logo and brand identity to empha-size the company’s leading capabilities in precision craftsmanship of high quality automotive interior products, performance materials, and injection moulded components.

The company name was established in 2010 based on the organizations steadfast use of statistical process control, often measured by “Cpk” the process capability index used to monitor manufacturing accuracy and consistency. Visually the new logo showcases the Cpk name inscribed within a circle, the shape of perfection. The mark is displayed perfectly centered between two horizontal up-per and lower control limit lines. With a company culture focused on perfection and exceeding customer expectations, “Precision Inside” has been established as the official tagline for the company. “Today we are extremely proud to unveil our bold new identity,” said Doug Gouin, Chief Executive Officer of Cpk. “Our brand heritage is built on a platform of delivering exceptional quality and craftsmanship to leading automotive brands. The new tagline and logo emphasize our employees’ dedication to precision in every phase of the product development and manufacturing process.” Through a collaborative effort across Cpk locations in Port Hope, Guelph, and Belleville Ontario, the identity roll out in-cludes a new website at www.cpkip.com along with facility signage, an employee newsletter and a newly designed marketing collat-eral system. Recently the company launched the new premium interiors for the Dodge Charger Rally Plus, listed as one of the Ward’s Automotive 10 Best Interiors for 2011. The Charger was chosen after Ward’s editors drove 51 vehicles that re-ceived significant upgrades or were completely new for the 2011 year. “Cpk continues to gain recogni-tion as a leading supplier of high quality interiors,” said Robert Varsanik, General Manager for Cpk. “Our investments in employee training and dedication to world class manufacturing processes are the cor-nerstone to the consistent results our customers rely on. The new tagline “Precision Inside” is the per-fect depiction of our company mindset and ultimately the value we offer to the market.”

Specials

For the month of August 2011 we are intro-ducing Employee Bonus Cash of up to $2,500 on the following models: $2,500 Bonus Cash on 2011 Jeep Grand

Cherokee $1,500 Bonus Cash on 2011 Ram 1500

(excludes Regular Cab, ST & SXT Models) $1,500 Bonus Cash on 2011 Jeep Wran-

gler (excludes Wrangler Sport) $1,500 Bonus Cash on 2011 Jeep Wran-

gler Unlimited.

Congratulations to Linda Mil-ler winner of the $25 Gas Card. Linda’s brother took advantage of the plan and purchased a Dodge Journey between April 2011—

June 30, 2011! New Contest

Tell us if you have taken ADVANTAGE of the Chrysler Advantage Plan during the period of July 2011—September 30, 2011 for your chance to win a

$25.00 Gas Card. Send an email to cathy.klein@cpkip.ca or leave a message at 905-885-3526. Please provide your name, shift, supervisor

and the date and type of vehicle that you purchased. GOOD LUCK!

WELLNESS CORNER

Energy Drink: Not for Kids : A recent article in the journal Pediatrics suggests that

energy drinks can be dangerous for children and teens. Some of these products have four

to five times more caffeine than soda, as well as other ingredients that can intensify caf-

feine’s effects. Potential dangers include heart palpitations, seizures, strokes and even death. En-

courage your kids to use natural pick-me-ups such as increased sleep and exercise and safe drinks

such as water, seltzers or 100 % fruit juices.

Page 4

What’s New Around the Plant?

TV in Cafeteria

PowerPoint presentation showcasing

our greatest assets “Our People”

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New Recycling

Program/

Environment

Page 5

New Recycling Program/ Environment

ENVIRONMENT PILLAR AUDIT

☐ NO Incidents

ENVIRONMENTAL ACT

☐ RECYCABLE MATERIAL IN REFUSE BIN

☐ RECYCABLE IN WRONG CONTAINER

☐ REFUSE IN WRONG CONTAINER

☐ ENERGY: FANS, COMPUTERS LEFT ON

☐ ENERGY: EXTERIOR DOORS LEFT OPEN

☐ USING UNAPPROVED MATERIAL

ENVIRONMENTAL CONDITION

☐ RECYCLE CONTAINER MISSING

☐ RECYCLE CONTAINER COLOUR/LABEL WRONG

☐ SECONDARY CONTAINER NOT LABELLED

☐ ENERGY: COMPRESSED AIR LEAK

☐ WASTE STATION SIGN ISSUE

☐ COOLANT/WATER LEAK

☐ SINK/WATER FOUNTAIN USED FOR DUMPING

ENVIRONMENTAL SERIOUS CONDITION

☐ ENVIRONMENTAL SPILL/INCIDENT – CALL BRIEF DESCRIPTION OF EVENT

____________________________________________________________________ ____________________________________________________________________________________________________________________________________________________________________________________________________________ Time: __________________________ Date: _______________________________ Location: ____________________________________________________________

PROPOSED COUNTERMEASURES

☐ TRAINING/ONE POINT LESSON (OPL) ☐ COACHING

☐ KAIZEN/IMPROVEMENT ACTIVITY ☐ MAINTENANCE

ENVIRONMENT PILLAR AUDIT

The purpose of the audit is to support and bring about environmental compliance by identifying any inci-dents, acts or conditions which impact the environment so that we create a workplace that is both environ-

mentally responsible and committed to preventing pollution for the benefit of current and future generations. Instructions for completing the Environmental Audit Form are:

Fill the card out if any one of the following is observed: Environmental Act (Involving People) Environmental Condition (Involving Machines) Environmental Serious Condition (Involving for example: spills)

Put in the date, time and location, with a brief description of the event. Check the appropriate Act, Condition or Serious Condition box as well as Countermeasure All items will be tracked and recorded by the Environment Pillar Lead (Cameron Potts).

Again, the purpose is to bring about environmental awareness (not discipline). Your participation help to en-sure that CpK Port Hope’s achieves ZERO serious conditions, acts or incidents.

Prevention of Pollution

SEPTEMBER CHALLENGE

How many environmental unsafe acts and/or unsafe conditions can you spot in

your area? Help us make our surroundings more environmentally friendly by identifying areas

where we as a company can improve. Just take a look around, observe your surroundings and then

let us know.

Pick up an Environment form, on corresponding side, or from your Supervisor or Cam Potts, fill it in

and drop it off at either the Suggestion Box located outside the nurse’s station or in WCM Office.

The area that spots the most environmental unsafe acts or unsafe conditions will win a pizza lunch/

dinner for their entire group.

Groups are broken out as follows:

1st Shift

Group 1: Injection Operators, Defroster Grille, Technicians and Injection Tooling

Group 2: LX Console Line (incl. Technicians and Inspectors)

Group 3: LX I/P Line (incl. Technicians and Inspectors)

Group 4: LC Challenger, Service/Service Pack (incl. Technicians and Inspectors)

Group 5: LX Doors (incl. Technicians and Inspectors)

Group 6: Maintenance, Projects, HVAC, Electricians, Modular Tool Specialists

Group 7: Environmental, Janitorial, Compounders, Distribution/Warehousing and

Inventory Control Analyst

Group 8: Colour & Analytical Lab, Quality & Dimensional Auditors, Tech Development,

Automation Techs, Pour Mold Tooling and Coating Set-Up

2nd & 3rd Shift

Group 9: Injection Operators, Defroster Grille, Technicians and Injection Tooling

Group 10: LX Console Line (incl. Technicians and Inspectors)

Group 11: LX I/P Line (incl. Technicians and Inspectors)

Group 12: LX Doors (incl. Technicians and Inspectors)

Group 13: Maintenance, Projects, HVAC, Electricians, Modular Tool Specialists

Group 14: Environmental, Janitorial, Compounders, Distribution/Warehousing and

Inventory Control Analyst

Group 15: Colour & Analytical Lab, Quality & Dimensional Auditors, Tech Development,

Pour Mold Tooling, Automation Techs and Coating Set-Up

MISSIO

N Z

ER

O C

HA

LL

EN

GE

Page 6

Wel

com

eW

elco

me

Wel

com

e

The Company would like to wel-

come the following new

employees:

Michelle Atkinson

Steve Baker

Kurt Brown

Marlee Carr

Lori Chapple

Crystal Cole

Mike Coull

Stephen Curl

Bryan Curtis

Jocelynn Gillespie

Aleysha Giroux

Jeff Hagerman

Jamie Hubbard

Doug Jackson

Stephen Jones

Megan Kneilands

Ross Learmonth

Cindy Lewis

Justin Linton

Brenda Matiyek

Martha Pickard

Kayla Riley

Tyler Roffey

Richard Spadafore

Courtney Sutton

Lindsey Woodward

William Young

Wayne Peddle, Information Systems

Analyst

Thanks to a suggestion we have cre-

ated a spot on our Innova-

tion...Ingenuity… Involvement board

that highlights new employees, and

will provide Department news and

updates.

Page 7

When the world

says “give up”

Hope whispers

“Try it one more

time”

AnniversariesAnniversariesAnniversaries

Congratulations to the following Congratulations to the following Congratulations to the following

employees for celebrating 35 Years of Serviceemployees for celebrating 35 Years of Serviceemployees for celebrating 35 Years of Service

Harold Fenton, June 1st Harold Fenton, June 1st Harold Fenton, June 1st

Sheila Stickan, August 25thSheila Stickan, August 25thSheila Stickan, August 25th

Cathy Lennan, August 30thCathy Lennan, August 30thCathy Lennan, August 30th

Derek Schieman, August 30thDerek Schieman, August 30thDerek Schieman, August 30th

Obstacles are those frightful things you see when you take your eyes off your goal. ~Henry Ford

MOTORCYCLE PARKING

Please note that there are currently 14

parking spaces available for motorcycles.

9 on the south/west side of

the plant and 5 on the east.

Bereavement Donations If an immediate family member passes away the Company will provide as a good will gesture either a floral arrangement or a do-nation to the charity of choice in memory of your loved one. The employee must advise Human Resources of the following:

Name of deceased

Relationship

Your choice of flowers or a donation

Name and location of funeral home If you have any questions, please contact the Human Resources Department. Thank you

Are you interested in join-

ing a Weight Watchers

program right here at CpK?

Weekly meeting times

would be arranged in an

attempt to accommodate

both shifts.

If interested please contact

Carolyn Gray at ext. 232 .

Cost is $150.00 (includes

HST) for a 10 week ses-

sion.

Let’s Play Ball

When: Saturday, Septem-

ber 10th

Time: 12 pm—4 pm

Location: Legion Fields, Cobourg

Who: Salaried vs. Hourly

If you are interested and

haven’t yet signed up

please Contact Steve

Henry at ext. 570 .

UNITED WAY CAMPAIGN

Thank you to everyone

who supported our

United Way BBQ on June 29th, we

raised $608.92

Innovation….Ingenuity… Innovation….Ingenuity… Innovation….Ingenuity… COMMUNITYCOMMUNITYCOMMUNITY InvolvementInvolvementInvolvement

Do you or someone you know do great things in the community? We want to

hear from you. We are creating a Community Involvement board on the wall just

west of the east Turnstile exit that will highlight what our employees do in our

community. Let us know if you know someone who is

Making a Difference!

Peter Czulo left, and Al Glover from

Cameco prepare the base for a new

bench at the Ruth Clarke Activity Cen-

tre during the United Way Day of Car-

ing on June 3rd, 2011

Sandi Lachner signs the survivor

banner at the 8th annual North-

umberland Relay for Life at St.

Mary Catholic Secondary School

on June 3.

Page 8

Dwayne Miller regularly donates

blood at the local Red Cross Blood

Drives. Dwayne has been six times

this year alone. One small gift that

keeps on giving.

Only change creates improvements.

Thank you to everyone who signed the Mission Zero poster. Everyone who signed had their name put into a draw for their chance to win the two WCM parking spots for the month of July. Congratulations to Rosa Hulme and Terri Ward for having their names drawn and winning two of the four WCM Parking Spots for the month of July.

Thanks to a suggestion by Dwayne Miller you will see containers in both cafeterias and the

WCM office where you can leave your aluminum tabs from your canned drinks. Working with

the Royal Canadian Legion we are working to accumulate enough tabs to purchase a wheel-

chair.

2,000,000 = 1 Wheelchair

TELL US HOW WE ARE DOING? Thanks to Cheryl See’s suggestion we made our newsletter bigger and the print larger. If there is something you like or would like to see different, drop us a note in either WCM Suggestion Box .

_________________________________________________________________________________

_________________________________________________________________________________

_________________________________________________________________________

Congratulations to Mike Matiyek, Bill Fox, Camilla Carr and Andres Gutierrez for winning the WCM Preferred Parking spots for the month of August. All four submitted suggestions in the month of July.

Page 9

WOULD YOU LIKE A CHANCE TO WIN ONE OF TWO WCM PREFERRED PARKINGS SPOTS FOR THE MONTH OF SEPTEMBER?

Thanks to a suggestion put forth by Wanda Finnemore we are putting forth a quick questionnaire to

see if we are being effective in recognizing the efforts/contributions that you make in WCM and Plant

Activities. Complete the questionnaire below and drop it off in either of the WCM Suggestion Boxes by

August 31st for your chance to win. Name: ________________________________

1. Did you know that thank you cards are sent out when a suggestion is received? Yes No

2. Did you know that we recognize 4 employees monthly for their suggestions ? Yes No

3. Did you know that we recognize employees in our newsletter (i.e. Face of Change and Community

Involvement segments) for their accomplishments? Yes No

4. Did you know we have a WCM Achievement case where we showcase our employees on a monthly

basis? Yes No

Would you like a second opportunity to win one of two WCM preferred parking spots for the

month of September? If so, take a minute and complete this month’s WCM Quiz. Complete

the quiz and drop it off at either the WCM Suggestion box located in the WCM office or out-

HEAT STRESS QUIZ Name: _________________________

1. What is normal body temperature? A. 96.8 º B. 98.6 º C. 99.8 º D. 106 º

2. True or False. To maintain your body’s internal “balance” you must replace both fluids and minerals?

True _________ False _________

3. The most serious heat-related illness is …?

A. Heat stress B. Heat stroke C. Heat exhaustion 4. In hot environments how much water can the average person’s body lose in an hour through

sweating?

A. A pint B. A quart C. A gallon

INNOVATION...INGENUITY...INVOLVEMENT

Employee Suggestion Program FACE of CHANGE May Winners

Page 10

Thank you to everyone who made a difference in the month of May and contributed to our Em-

ployee Suggestion Program. Congratulations to Wanda Finnemore and Jamie Ward, winners the

WCM Preferred Parking Spots, along with the following individuals for each winning the monthly

awards and a $25 gas card in the following categories:

Lisa Ferguson For her suggestion and contribution in the area

of Environmental Improvement within our workplace

Diana Roddy For her suggestion and contribution in the

area of Safety within our workplace.

Gary Rowe For his suggestion and contribution in deploy-ing WCM Knowledge throughout the Organi-zation. Gary suggested that we deploy group

efforts on our plant floor in order to get WCM projects done.

Saundra Hrncir For her suggestion and contribution in deploy-ing Creative Thinking throughout the Organi-zation. Saundra suggested that we donate our gently used safety shoes to Habitat for Human-

ity.

INNOVATION...INGENUITY...INVOLVEMENT

Employee Suggestion Program FACE of CHANGE June Winners

Page 11

Thank you to everyone who made a difference in the month of May and contributed to our Em-

ployee Suggestion Program. Congratulations to Cathy Klein and Regina Butler, winners the

WCM Preferred Parking Spots, along with the following individuals for each winning the monthly

awards and a $25 gas card in the following categories:

Dwayne Miller For his suggestion and contribution in the area of En-vironmental Improvement within our workplace. Dwayne’s name was chosen from all those that

were submitted in the area of Environment.

Mike Brown For his suggestion and contribution in the area of Safety

within our workplace. Mike’s name was chosen from all those that were submitted in the area of

Safety.

Richard Alexander For his suggestion and contribution in deploying Creative Thinking throughout the Organization.

Richard’s suggestion to reduce oil pad usage while considering the cost benefit exemplifies his

commitment to World Class Manufacturing

Derek Schieman For his suggestion and contribution in de-ploying WCM Knowledge throughout the

Organization. Derek suggested that we put signs up near the WCM Pillar Temple

to remind people to watch for forklifts.

Help us

reach our

goal!

Our goal is to reach 1,200 suggestions by the end of 2011 or 3 suggestions per employee. As of Ju-

ly 31st, we were at 315 valid suggestions, well below where we need to be; 34% of us have sub-

mitted at least 1 suggestion and 13% have submitted 3 or more. We need your help to reach our

goal and please don’t get discouraged as each and every suggestion is being review and acted up!

Page 12

Employee Suggestion Program Update

“It is not the strongest of the species that survives, not the most intelligent, but the one most responsive to change.” Charles Darwin

Would you like to know how many points you have? Effective September 1st a listing by employee number will be displayed on the Innova-

tion,...Ingenuity...Involvement on a monthly basis. Please note that you can follow up on on the status of your suggestion at the WCM office