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Conference
Program -- Measurement Track
Improving Plant Performance by Managing Asset Utilization and Availability 10:00 a.m. -- 11:00 a.m. If meeting production schedules is important to you, then you should attend this session on best practices for maintenance management. ARC Advisory Group recently completed research into current practices for Maintenance Management. This session will review the research results and make clear, unambiguous recommendations for improving your operational performance. One hundred and two manufacturers responded to our survey that provided structured data for analysis and strong conclusions. Additionally, 10 of the respondents volunteered for extensive individual interviews that helped to improve the interpretation of the survey data. Additional insights where gained through these personal interviews with managers of maintenance. The responses were categorized in a manner that allows ranking and comparison of Leaders, Competitors and Followers. Comparisons are made across the dimensions of People, Processes, Technology and Metrics. In each of these dimensions, specific business practice differences between the Leaders and Followers are highlighted. Maintenance insures equipment uptime so production can meet its schedules. Unfortunately, maintenance is often viewed as a cost center that is associated with the "L" side of the P&L statement. Then, maintenance becomes a cost to be managed and reduced which leads to operational problems and under-performance. Maintenance is a critical component of the production system that is needed to achieve revenue, quality and margin targets. There is a clear connection to the top line in the P&L statement, i.e. from maintenance to production and then revenue. By attending this session, you will gain an understanding of best practices and learn from the leaders. Speaker  Jim Caie, Vice President, Consulting,
ARC Advisory Group
Jim Caie leads the ARC team serving the automotive and other discrete industries. He has over 20 years experience in executive leadership roles, formulating and executing successful manufacturing engineering strategies. He has excellent working knowledge of operations research methods, simulation, lean manufacturing, and controls engineering. Prior to joining ARC, Caie spent 36 years with General Motors Corporation. His most recent position was director of controls, conveyors, robotics, and welding (CCRW), where he led development and validation of common, global CCRW architectures, standards, and specifications for GM assembly and fabricating plants. In addition, Caie established capability to effectively design and deploy CCRW systems; led the deployment of plant floor systems for all North American car and truck programs (averaging 8 plant sites per year); and led the development, validation, and deployment of controls, networking, and robotic systems for all North American press and hydroforming projects. Caie's management of GM's common global manufacturing controls architecture activity resulted in over $100 million/year savings for equipment investment, 25% GM's Factory of the Future project to create a highly flexible, "lights out" (zero direct labor) factory for front wheel drive axles. He also led development and first GM deployments of critical manufacturing technologies, including open communication networks (MAP), cell control, PC-based controls and operator interfaces (HMIs), safety PLCs and monitored power systems, programmable flexible fixtures, predictive maintenance using artificial intelligence, and emulation for control logic validation. Caie served in the Michigan Army National Guard, holding personnel, logistics, training, and command leadership positions in artillery, armor, infantry, and military intelligence operations, retiring as a Full Colonel. He holds a master's in business administration as well as a master's and bachelor's in industrial engineering from the University of Michigan. How and Why to be an IW Best Plants Winner 11:15 a.m. -- 12:15 p.m. IndustryWeek Best Plants awards coordinator Jill Jusko, will discuss the benefits of being an IW Best Plant and walk attendees through the IW Best Plants application, highlighting key questions and providing insights into performances achieved by past participants. Speaker  Jill Jusko, Senior Editor & IW
Best Plants Award Program Coordinator, IndustryWeek
Jill Jusko coordinates IndustryWeek's Best Plants Program, which annually salutes the leading manufacturing facilities in North America. She has been a member of the IW Best Plants judging team since joining the IndustryWeek staff in 1998 and was named coordinator of the program in late 2004. Jusko also has served as the editorial project director of the IW/MPI Census of Manufacturers and as new media editor of IndustryWeek.com. In her position as senior editor, Jusko is responsible for covering the consumer products industry and energy-related issues. Six Sigma: Choosing the Right Projects 2:00 p.m. -- 3:00 p.m. Six Sigma initiatives have reached their maturity in most manufacturing environments and in others are at the beginning stages. In order for Six Sigma projects to make an impact on a company's bottom line, the right projects must be chosen. Ron Atkinson, chairman of the American Society for Quality board of directors, will address the process of selecting the right projects that will effectively and efficiently grow an organization. Learn how to develop a Six Sigma project portfolio that outperforms projects selected through non-portfolio type methods, and how to link project selection to critical issues and business goals. Speaker  Ronald D. Atkinson, Chairman of
the Board, American Society for Quality (ASQ)
Ron Atkinson uses quality every day in his role as Quality Systems Manager for General Motors and says the tools and processes are integral to his personal life as well. He has been an ASQ member for more than 20 years, many of them as a member leader representing ASQ's Divisions in director and chairman positions. Atkinson has been on the ASQ board of directors for seven years. He has also served in many local and national positions in the Society. He holds ASQ certifications as a Six Sigma Black Belt, quality engineer, auditor, manager, and quality improvement associate. He is also on the Board of the China Association for Quality. For more than 30 years, Atkinson has worked for General Motors, with the majority of that time in quality-related activities. Atkinson spent six years on the Michigan Quality Council (Baldrige based) examining board. He has taught classes on many quality-related subjects at several educational institutions in the United States and has also been on the curriculum advisory board for three U.S. colleges. He holds a master'd degree in industrial engineering from Wayne State University, a master's in business administration from Louisiana State University, and a bachelor's of applied science in mechanical engineering degree from the University of Waterloo, Ontario, Canada. Benchmarking: Why, What, Who & How To 3:15 p.m. -- 4:15 p.m. Benchmarking is a tool all manufacturers should employ to gauge how well they are performing compared with others and to learn about best practices that will boost their performances. This session will aid in your benchmarking strategy, helping you understand the importance of benchmarking, what performance metrics to benchmark, who you need to benchmark against and how to execute your strategy. Speaker Alison Smith, Research Director, AMR Research, Inc. Alison Smith brings more than 25 years of manufacturing software development, support, marketing, and sales experience to her role as a research director in AMR Research's market services group. Smith is dedicated to the detailed study of the productive application of information technology to the challenges faced by global producers as they seek to implement and evolve demand-driven manufacturing strategies. Smith's current research focus is manufacturing operations. She publishes frequently on the application of manufacturing operations software, including manufacturing execution systems, enterprise manufacturing intelligence, and asset performance management across a range of vertical industry manufacturing scenarios. She is currently investigating global specification management for process industry manufacturers. Prior to joining AMR Research, Smith was a founding officer and marketing vice president of Framework Technologies Corporation. Smith has also held various management positions with several software companies, including Mainstream Software Corporation, Decision Software Company, Microtouch Systems, and Cyborg, a provider of data acquisition and chromatography workstations sold to the laboratory R&D environment. Smith graduated summa cum laude with a bachelor's from the University of Wisconsin. Thursday, April 3 Solving the Standard Costing Problem in Lean Manufacturing 8:45 a.m. -- 9:45 a.m. Standard costing -- and other full absorption product costing methods -- is actively harmful to the lean manufacturer. Traditional standard costing methods calculate the product costs wrongly, they lead to bad decision making that in turn lead to reduced revenues & lower profitability, and the processes required to maintain a standard costing system are complex, time-consuming, and very wasteful. In addition, standard measurements like earned hours, efficiency, machine utilization, and absorption variances actively undermine what we are trying to achieve through lean transformation. This workshop will show how value stream costing is used instead of standard product costing to provide excellent control of costs, valid and meaningful information for decision-making, and the financial numbers required for external GAAP reporting. We will discuss how to create a simple, summary direct costing of the value stream, weekly value stream income statements, and how this information can be rolled-up to provide month-end report for internal use and external reporting. Using a case study we will demonstrate how pricing, quoting, margin analysis, make/buy, sourcing, and other routine decisions can be made quickly and easily using value stream costing. Speaker  Brian H. Maskell, President, BMA
Inc.
Brian Maskell has more than 25 years experience in manufacturing and distribution industry. He has held a variety of management positions from the shop-floor of an electronics company to manager of European Inventories for the Xerox Corporation to vice president of product development and customer service of the Unitronix Corporation. Over the past ten years Maskell's consulting practice has taken him to many manufacturing and distribution companies in the United States, England, Mexico, Australia, South Africa, and Europe. He has assisted these companies in the implementation of advanced manufacturing techniques including lean and agile manufacturing, logistics and supply chain management, lean accounting, value-stream costing/management, new performance measurement, process re-engineering, enterprise information systems, and total quality management. A sought-after speaker, Maskell is the author of six books including; Practical Lean Accounting (2003), Performance Measurement for World Class Manufacturing (1991), Software and the Agile Manufacturer (1993), New Performance Measures (1994), Making the Numbers Count; the accountant as an agent of change (1996), and the software product Putting Performance Measurement to Work (1999) from Productivity Press. Maskell's works address the needs of manufacturers as they move into the increasingly competitive 21st century. Maskell conducts seminars and workshops around the world on such subjects as Lean Accounting, Performance Measurement for World Class Manufacturing, Lean Manufacturing, Software and the Agile Manufacturer, Value Stream Cost Management, Target Costing, and Agile Manufacturing. Maskell has an engineering degree from the University of Sussex, England. He is certified with the Chartered Institute of Management Accountants in London, the American Institute of Certified Public Accountants, and is a Fellow of the American Production and Inventory Control Society. He is the author of numerous articles and papers and regularly presents papers at national and international conferences. Accelerate: A Powerful Model for OEM Supplier Development 10:00 a.m. -- 11:00 a.m. "Accelerate," a powerful model for OEM Supplier development was developed by a consortium of WMEP, Oshkosh Truck Corporation, John Deere Company and Harley-Davidson in FY 2005. This model has now been adopted by 16 major OEMs, and has been delivered by 26 MEPs in 21 States to over 250 Suppliers. This four step model combines the use of two powerful tools; the Lean tool of Value Stream Mapping (VSM) and the University of Wisconsin-Madison Center for Quick Response Manufacturing tool of Manufacturing Critical-path Time(MCT) to develop results for both the OEM and the Supplier. Mike Hablewitz of the WMEP will describe the four-step approach. Sean Ketter of Oshkosh Truck Corporation will describe Oshkosh Truck Corporation overview of their supply chain initiative based on 100 suppliers using the "Accelerate" model; results that traditional metrics of quality, delivery and cost have improved; the creation of supply chain flexibility; and how "Accelerate" based supply chain performance support OTC growth and profitability goals beyond simple piece price. Mike Dougherty of D&S Manufacturing, a supplier to Oshkosh Truck Corporation, will give his perspective and describe their results from using the "Accelerate" model. Speakers  Mike Hablewitz, Director, Supply
Chain, WMEP
Mike Hablewitz is the director, supply chain group with Wisconsin Manufacturing Extension Partnership (WMEP) with over 30 years of experience in operations management. He has specific expertise in the areas of strategic planning; leading organization change; total quality management including implementing ISO 9001:2000 Quality Management Systems; materials, supply and value chain management; team empowerment; and implementing focused factories utilizing lean manufacturing concepts. Hablewitz received the prestigious Practitioner Award from the Modernization Forum, Manufacturing Extension Partnership, National Institute of Standard and Technology for his distinguished record of direct service to small and midsize manufacturers. Hablewitz has degrees from the Milwaukee School of Engineering (MSOE) in Industrial Engineering and in Industrial Management; and a Masters in Management from the J.L. Kellogg Graduate School of Management, Northwestern University. Hablewitz's previous Industry experience includes positions as Director of Manufacturing Operations with a metals manufacturer where he managed three divisions and corporate engineering and quality, implementing QS9000; and positions of vice president of quality, vice president of manufacturing, vice president of materials with an international manufacturer and distributor of power transmission systems, implementing lean techniques while restructuring into focused factories and ISO 9001 and ISO 9002 throughout the world wide organization. Hablewitz is a Certified Fellow in Production and Inventory Management (CFPIM) from the American Production and Inventory Control Society (APICS), past president of the Milwaukee Chapter of APICS, past Vice President of Education and Research for International APICS. Hablewitz is also a senior member of Society of Manufacturing Engineers (SME), and member of Association of Manufacturing Excellence (AME) and American Society for Quality (ASQ).  Sean
Ketter, Manager, Enterprise Supplier Development, Oshkosh Corporation
Sean Ketter is manager, corporate supplier development for Oshkosh Corporation. Ketter joined the company in March 2006. He is responsible for developing and deploying supplier development strategies and tools across the entire enterprise. Ketter will also be assessing the order fulfillment capabilities of Oshkosh's current supply base and make recommendations on how to further develop and align a lean supply chain. This role requires a cross functional approach, integrating purchasing, quality, engineering, marketing and suppliers. Before joining the company, Ketter held several positions in supply management at Deere & Company, including strategic sourcing, product development, and supplier development. Ketter holds a bachelor's in industrial engineering and a master's in manufacturing systems engineering both from the University of Wisconsin at Madison.  Mike
Dougherty, President, D&S Manufacturing
Mike Dougherty is President of D&S Manufacturing, which is located in Black River Falls, Wisconsin. During his nearly three decade tenure, the last sixteen as president, Dougherty has transformed the company from a small job shop with one primary customer into an integrated manufacturing firm that supplies complex fabrications and weldments to Fortune 500 corporations in a broad spectrum of market segments. He was responsible for leading the development of the company's ISO certified quality system and is now the driving force behind the organization's lean manufacturing initiatives. While serving as a supplier representative on the Wisconsin Manufacturing Development Consortium, Dougherty worked with WMEP and OEM members of the Consortium in assisting Wisconsin companies in their implementation of lean manufacturing techniques. Dougherty is actively involved in various community and civic organizations, including the Black River Area Foundation Board of Trustees, and serves on the Board of Directors for Jackson County Bank. He has been a member of the Wisconsin Manufacturers and Commerce Board of Directors since 2003. Dougherty is a graduate of Carroll College with a bachelor's in business administration. Performance Metrics that Matter: Choosing Information Over Data 11:15 a.m. -- 12:15 p.m. Computer-based Automation and Information Systems have been deployed in industrial operations for decades often with less than spectacular results. There are many contributing factors involved including abnormal focus on the technology rather than plant performance, difficult to traverse organizational silos and death-by-initiatives. As the technology has advanced in capability it has finally begun to realize its true potential. The first step in the move to getting incremental business value from industrial assets is the development of effective and empowering performance metrics right for each person and group in the plant. The evolution of real-time performance measurement systems that are driving new levels of business performance in industrial plants will be presented. Speaker  Peter G. Martin, Ph.D., VP and GM of
Performance Management, Invensys Process Systems
Dr. Martin joined The Foxboro Company in the 1970's and has worked in a variety of positions in training, engineering, product planning, marketing and strategic planning. He left Foxboro to become vice president at Intech Controls and also at Automation Research Corporation before returning to Invensys in 1996. Since his return he had been VP of marketing for Foxboro and chief marketing officer for Invensys Manufacturing and Process Systems prior to moving into his current position. He has authored numerous published articles and technical papers and has written two books: Bottom Line Automation and Dynamic Performance Management: The Pathway to World Class Manufacturing . Dr. Martin holds multiple patents including the patent for Dynamic Performance Measures, Real-Time Activity-Based Costing, Closed-loop business control, and Asset and Resource Modeling, which are the basis for Fortune recently naming him a Hero of U.S. Manufacturing. He was also recently named as one of the 50 Most Influential Innovators of All Time by the Instrument, Systems and Automation Society (ISA). Dr. Martin has bachelor's and master's degrees in mathematics and an master's degree in administration and management, a master's of Biblical Studies degree, a Ph.D. in Industrial Engineering, and is in the process of completing his PhD in Biblical Studies. Actual Conference speakers, topics, and sessions may have differed slightly from this listing. Last Updated March 3, 2008. |
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