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Joe Buonodono
Johnson Controls Inc. CI Manager, Business Process Improvement
Adding Enterprise-Wide Value to Your Organization
Organizations can gain a competitive advantage through better engineering, better innovation and through faster, more effective problem resolution and continuous improvement efforts. By focusing on the latter, Johnson Controls
has saved millions of dollars. The catalyst is building capability in your people.
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Discussion Outline
Introduction of JCI
JCI approach to building capability in its people
• Leadership Institute training • KT Practitioners • Triple certification
Case studies Tangible Results Questions
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Approximately 150,000 employees worldwide Three main businesses: Building Efficiency, Automotive Experience and
Power Solutions
Brief Background of Johnson Controls
Johnson Controls celebrates 125 years of making buildings more energy-efficient for
its customers. The company was founded in 1885 by Professor Warren Johnson
following his invention of the first electric room thermostat. The invention launched an industry dedicated to energy efficiency,
through the regulation of temperature room-by-room in homes and commercial
buildings.
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JCMS Path to Operational Excellence
Integrate into Daily Work
Control
Improve
Analyze
Measure
Define
Recognize
Brief Background of Johnson Controls
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The KT Rational processes and icons
JCI’s approach utilizing KT: Educate And reinforce capability
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KT Rational Processes Removal of Special Cause
Situation Appraisal (SA)
Problem Analysis (PA)
Potential Problem Analysis (PPA)
Lean Removal of Waste
Six Sigma Removal of Common Cause
KT Continuous
Improvement Prioritization & Resource
Assignment
Situation Appraisal (SA)
Decision Analysis (DA)
Potential Problem Analysis (PPA)
Potential Opportunity Analysis (POA)
Brief explanation of Triple Certification
JCMS
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We communicated KT throughout the company and its importance to individual development
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Internally created website for information, training, & knowledge
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Training
Execution
Results
We have systems that measure not “just” training, but execution and results
Learning Management System
Projects in CI Trac
$, Quality, Safety, etc in CI Trac
We created the “Practitioner Certification”
The landscape of training and certification
# of people trained
# of projects completed
Needles moved
This was the line in the past
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Three Steps to Kepner-Tregoe Practitioner Certification
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M.C. attended KT training recently, and used the PSDM tools on a new launch problem that occurred at her plant shortly afterward. The total savings for the project are over $60,000, and it is a very
good example of the application of the tools
JCIM Southview Facility Application
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Definition of the problem
The problem was a new launch product. It was a vehicle door panel that had a thin foam strip around the back of the part.
The defect was that the foam was peeling away from the door panel
Result:
Additional Labor
Additional Time
Added Material cost
To try and reduce the effects, a separate station was put in place. Additional foam was being placed over the corners to try and keep the foam down
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Specification and Identifying Cause
Because this was a NEW LAUNCH, the IS-NOT was developed by finding another
closely related product
M.C. used Distinctions and changes to uncover some key differences between
her door panel and the IS NOT door panel
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Determine Most Probable Cause, Verify
The adhesive on the foam was discovered to be incompatible with the lamination process used on this door.
A better, lean solution was to use a different adhesive, that in addition to being less expensive, allowed the team to apply the perimeter foam within the cycle time of an existing assembly process.
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Case example using KT during Lean Event
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P. M. in his plant after Kaizen
P.M. used the PSDM tools to bring several improvements together, and he used DA to help select a new layout for his improved line.
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P.M. using the DA with Lean
Not all decisions have to “hit” paper, but making the thinking visible helps drive team consensus, in this case the team did use the KT template
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Value beyond financial measures…
S. C. $28,000 savings from KT Projects
S.B. $28,000 savings from KT Projects
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Additional examples Vinyl defects on Door Panel program
Seat Travel sensor
Vinyl adhesion for OEM PAB Sonic Welded component
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Questions / Comments
Sam Bernstine Automotive Practice Leader
Kepner-Tregoe, Inc.
Joe Buonodono
Johnson Controls Inc. CI Manager, Business Process Improvement
Office: +1/ 609-252-2417
Mobile: +1/ 724-944-9169