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Conference
Program -- Advanced Continuous Improvement Track
Lean Success in a Low Volume - High Mix Manufacturing Setting 10:00 a.m. -- 11:00 a.m. Facing a resurgent domestic market and a growing global demand, Card-Monroe Corp. (CMC), the 27-year-old company turned to lean manufacturing in 2003. The challenge of a low volume – high mix manufacturing environment was creating rising costs and late deliveries. CMC created a unique blend of lean tools, selected to match their specific challenges, completely revamping their approach to manufacturing. The concepts and tools utilized include; lean purchasing, theory of constraints, 5-S, single-piece-flow, demand-pull scheduling, rapid setups and changeovers, cellular manufacturing, synchronous flow, standard work, kanbans, and lean product development. Results of the lean initiative include; 80% growth in sales, 35% increase in productivity, 75% reduction in WIP, 300% improvement in on-time shipments, and a 60% decrease in manufacturing cycle time. Jim Joyner will share the CMC lean transformation experience, including why the company almost gave up before discovering the right tools and concepts for their environment. Speaker Jim Joyner, Director of Lean, Quality & Service, Card-Monroe Corp. Jim Joyner began his career at the 3M Company where he first helped install the principles of Total Quality. In 1983, he joined Philip Crosby Associates, which grew to become the world's largest consulting company specializing in quality management. In 1991, he formed his on consultancy and engaged clients on six different continents. Joyner has taught lean and quality to thousands of managers in hundreds of seminars around the world. Joyner has been the Director of Lean, Quality & Service at CMC since 2003. Ready, Set, Change: Shifting from Push to Pull Production Successfully 11:15 a.m. -- 12:15 p.m. Unreliable sales forecasts can be the downfall of push manufacturing, resulting in excess or obsolete inventory, and wasted dollars. Learn how to transform your manufacturing environment to one that instead builds to actual customer demand. Speaker  Herb Bradshaw, Director of Lean
Enterprise & Plant Manager, Thomas & Betts Corp. -- 2005 IW Best Plants
Winner
Herb Bradshaw is plant manager of 2005 IW Best Plants Winner, Thomas & Betts Corp. -- Athens, TN operations. With Thomas & Betts since 1982, he has held positions in corporate & division engineering, operations management and project management. Bradshaw most recently chaired an international team that developed the Thomas & Betts Manufacturing System that documents the company's Lean philosophy and "How We Work" as an operating enterprise. He holds a bachelor's degree in industrial engineering and a master's degree in engineering administration from the University of Tennessee -- Knoxville. A Look at Extending the Value Stream Map: A Case Study with Ford & Tier 1 Supplier Rieter Automotive 2:00 p.m. -- 3:00 p.m. Learn how Ford's Value Stream Mapping process reduces cost while not effecting a supplier's operating margin. Brown will discuss their process of data acquisition, drawing the map, analyzing the map and managing the opportunities as well as demonstrate unique analysis tools that simplify the VSM process. Speaker  Mel Stojakovich -- Manager of
Continuous Improvement, Magee Rieter -- 2006 IW Best Plants Winner
Mel Stojakovich is the manager of continuous improvement for Rieter Automotive Carpet operations (formerly Magee Rieter Automotive Systems). He is responsible for the overall continuous improvement efforts of Rieters North American automotive carpet operations located in Bloomsburg, PA, Shreveport, LA, and London, ON. Rieter's North American automotive carpet operations have approximately 800 associates and are represented by the UNITE HERE! formerly the Union of Needletrades, Industrial and Textile Employees. Stojakovich holds a bachelor's degree in business administration from West Virginia University and continued with graduate studies in Industrial Labor Relations at Cornell University. He has held a variety of corporate and manufacturing positions of increasing responsibility in industrial engineering, human resources, and operations management throughout his professional career. His passion is engaging shop floor associates in identifying areas of waste and opportunities for product and process improvements. He has been a key team member of the Rieter Automotive carpet business for four years. He helped lead the Bloomsburg Operation into one of the top manufacturing facilities in North America with its recognition as a Top 25 IndustryWeek Best Plant finalist in 2005 and a Top 10 IndustryWeek Best Plants winner in 2006. The Rieter leadership team follows the guiding principle of involving all associates on the team beginning with regular and ongoing communications related to both the day to day operations, and performance to established operational goals. Much of the success at the Bloomsburg plant can be attributed to associates being actively involved by bringing forward new ideas and solutions and the sense that we are all in it together. Value Innovation: Driving Lean Product Development Using Voice of Customer and Value Innovation Curves 3:15 p.m. -- 4:15 p.m. Vermeer operates under a set of core values that revolve around people, profit and product. These principles are incorporated into the company's mission statement: "Taking care of customers worldwide with better solutions." Join Vermeer and TBM Consulting Group in a discussion about their approach to driving organic growth in a relatively mature industry. Find out how Vermeer has transformed into a client-driven company that embraces innovation. Understand how Vermeer has leveraged its lean discipline to drive product development and ultimately deliver meaningful, differentiated product innovations. Learn how you can drive product innovation by becoming a product-driven, market-focused, listen-and-serve company by using growth tools including voice of customer and value innovation curves. Speakers Mark Core, Vice President of Forage Management, Vermeer Manufacturing Company 
Gary Hourselt, Executive Vice President, TBM Consulting Group, Inc.
A former senior executive in the aerospace industry, Gary Hourselt brings broad experience in lean business strategy development and deployment to TBM's International offices. Hourselt was recruited as president of Huck Fasteners before joining TBM, and previously served as president of the company's industrial and aerospace divisions. During his five years with the company, revenues roughly doubled and pretax income grew by a factor of seven. He also led the acquisition and integration of four businesses in four years. Over the years, Hourselt has led companies throughout the U.S., Canada and Mexico, and in China, Japan, Italy, Germany, France and Britain. Hourselt is also a Certified Public Accountant who began his career as a controller and operations manager before moving on to become vice president and general manager of Senior Flexonics OEM Division. He has been a lean practitioner since 1990. Hourselt has an master's in business administration from Northern Illinois University and a bachelor's degree from Aurora University. Thursday, April 3 Energy Efficiency as a Competitive Advantage 8:45 a.m. -- 9:45 a.m. Learn to use energy efficiency as a competitive advantage. Johnson Controls will discuss how they have used it in their facilities and provide concrete way to apply energy efficiency solutions within your own facility. Speakers Clay Nesler, VP, Global Energy and Sustainability, Johnson Controls Clay Nesler is the Vice President, Global Energy and Sustainability for Johnson Controls, Inc. In this role, he leads a global team responsible for coordinating marketing, legislative affairs, resource management, product/service innovation and energy program management. Nesleralso leads a professional services organization that develops collaborative planning tools and provides consulting services to Johnson Controls customers and third-party clients on a global basis. Since joining Johnson Controls in 1983, Nesler has held a variety of leadership positions in technology, new product development and marketing in both the United States and Europe. He received his bachelor's and master's degrees in mechanical engineering from the University of Illinois at Urbana-Champaign and is listed as a co-inventor on ten patents. Kevin Shelton, Director of Facilities, Johnson Controls Lean IT 10:00 a.m. -- 11:00 a.m. Based on Jean Cunningham's experience as CFO at two lean companies, learn what changes Operations, Sales and Finance will need in the ERP/MRP application and how to apply lean principles to the IT process. This is not a bits and bytes discussion! Speaker  Jean Cunningham, Consultant and
Author, Jean Cunningham Consulting
Jean Cunningham is co-author of Real Numbers: Management Accounting in a Lean Organization, 2004 Shingo Prize for Research recipient. She serves a number of clients with business strategy, process improvement, and growth and acquisition planning through out the U.S. She is the former chief financial officer and vice president of company services, responsible for accounting, human resources, information systems and telecommunications at both Lantech, LLC and Marshfield DoorSystems, Inc. From 1991 through 2004, Cunningham was a leader in Lantech's evolution of a small, family owned business to a lean industry leader. Lantech's Lean Journey was chronicled in the best seller, Lean Thinking. Cunningham joined the continuous improvement effort at Lantech from their first kaizen, and took the revolution of lean from the manufacturing floor to the business office of this Louisville, Kentucky manufacturer of packaging equipment. She was actively involved with Lantech's product expansion efforts through acquisition and product development. Prior to joining Lantech, Cunningham was a finance professional with Digital Equipment Corporation and Westinghouse Electric. She cut her teeth in the business world in her mother's business from age 12, later teaching school and managing a restaurant, which provided a base of practical experience. In addition to co-authoring Real Numbers she has contributed to several publications related to lean accounting and lean operations and has just released another book, Easier, Simpler, Faster; Systems Strategy for Lean IT. She has lectured on Lean Accounting and Operations Management on many occasions. Cunningham has a bachelor's in accounting from Indiana University and a master's in business administration from Northeastern University's Executive Program. She lives in Chicago area with her husband, Alan Riggs, and has two sons. Manufacturing 2.0 11:15 a.m. -- 12:15 p.m. Explore opportunities and challenges presented by the convergence of manufacturing engineering and information technologies. Speaker  Paul Boris, Senior Director, Perfect
Plant Center of Excellence, SAP
Paul Boris has over 20 years experience working with manufacturing firms to help them define and deliver sustained operational improvement. He started with General Motors in the Assembly Division and has run facilities encompassing all modes of manufacturing. Boris began applying his experiences to the deployment of advanced manufacturing technologies in 1996. He joined SAP in 2005 with the acquisition of Lighthammer Software and his current focus is on the delivery of next-generation systems to support adaptive manufacturing./font> Conference speakers, topics, and sessions are liable to change at any time. Last Updated March 17, 2008. |
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