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Sessions


36 sessions organized into tracks:  
Workforce Development
Manufacturing Technology Strategies
 
Keynotes

dan ariensPete Selleck, Chairman & President - Michelin North America Inc.

Pete Selleck is a 30-year veteran of Michelin. During his career, he has held numerous high-level management positions, including manger of quality control and tire assembly operations, plant manager, VP of Michelin Tire Manufacturing in the U.S. and Canada, COO of Michelin Americas Small Tire operations, and  President of worldwide Truck Tires. Today, as chairman and president of Michelin North America, Mr. Selleck is responsible for the coordination of all operations of the Michelin Group in North America that consists of 18 major manufacturing facilities and about 22,000 employees.

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dan ariensDan Ariens, CEO - Ariens Company

Lean Leadership: Learn. Develop. Sustain.

Ariens Company has experienced significant employee growth and added new manufacturing locations since the company originally started its lean journey in 1998. Its lean culture has enabled the manufacturer to achieve enviable levels of success. President Dan Ariens will discuss the role of a lean leader in ensuring that Arien's lean culture remains viable and dynamic for new employees who have not learned by shared experience. He will discuss the many tools that have allowed lean to thrive at Ariens, including a lean internship program, hands-on culture, lean development hours and an employee Lean Implement program.

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Rich Morris, VP Assembly - BMW Manufacturing Co.

Leading Sustainable Improvement
What is your leadership legacy? Vice President of Assembly Richard Morris' keynote address will provide a thought-provoking presentation of how great leaders effectively guide organizations through process change improvement. He will review BMW's commitment to profit before growth, lean manufacturing and continuous improvement as he shares examples of how BMW's plant in South Carolina has achieved remarkable success in the last 20 years.

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paul jeppesenPoul Jeppesen, CEO & President - SKF USA

SKF: Beyond Our Factory Walls -- How building closer business partnerships with our suppliers and customers, and closer participation with our local communities, creates a more productive and inclusive climate for change.

SKF manufacturing and quality control programs have evolved over the years to include people far beyond the company's own shop floors in reaching new levels of quality and performance.

Poul Jeppesen, president of SKF Americas, will describe SKF's approach of integrating its long-term sustainable development with its lean manufacturing processes and growth initiatives.

SKF's concept embraces the health and well-being of not only its employees, but also customers, communities and the shared global environment. By working to reduce its own environmental footprint, SKF has successfully reduced CO2 emissions while increasing output. Now under a concept called BeyondZero, SKF helps customers achieve similar reductions in their own plants by sharing best practices, and by creating new products and services that can reduce energy and resource use.

Underpinning this development is a “OneSKF” culture that encourages employees to think and work beyond their own situation or their business unit, and consider the impact on the total company including supplier partners. Then by applying lean methods, SKF Business Excellence systematically improves processes, products and services to deliver customer value in a meaningful, efficient and sustainable way.

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Reshoring: The Executive View
Moderator:  Harry Moser, Founder & President, Reshoring Initiative
Panelists:  John Higgins, CEO, Neutex Advanced Energy Group
Rick Marquardt, SVP of Global Operations, NCR

No industry phenomenon has received as much attention in recent years as the promise of reshoring manufacturing jobs and operations to the United States. A panel of manufacturing executives discusses why they decided to reshore, how the transition was handled and what they see for the future of this movement.

rick MarquardtPanelists: Rick Marquardt, Sr. VP, NCR Global Operations

Rick Marquardt is responsible for sales and operations planning, sourcing, supply chain operations, fulfillment and NCR's five internal manufacturing facilities.

Prior to this role, Marquardt served as vice president of Global Manufacturing for NCR where he was responsible for in-sourcing the company's manufacturing operations and opening up two new plants—one in Columbus, GA to service North America and the other in Manaus, Brazil to service Latin America.

Prior to this role, Marquardt was vice president of Global Operations for NCR's Financial Industry Business Unit, responsible for all aspects of operations including manufacturing, procurement, SIOP, and customer fulfillment. He joined NCR in 2006.

Marquardt also worked for Motorola Corporation, where he held increasingly responsible operations and manufacturing positions, including a four-year assignment in Taiwan and a one-year assignment in Mexico, managing operations with an excess of $1B spend annually.

His assignments have included vice president of Asia Manufacturing Operations, Motorola Connected Home Division; Vice president Mexico Manufacturing Operations, Motorola Connected Home Division; Vice president Global Operations, NCR Financial Solutions Business; Vice president Global Manufacturing, NCR.
Continuous Improvement Fundamentals

Zero is a Beautiful Number: The ‘Zero Optimum' Concept using World Class Manufacturing Tools
Speakers: Humberto Del Rio, Manager of World Class Manufacturing, Case New Holland
Eddie Smith, Manager of Operations, Case New Holland

How many losses are acceptable? ZERO. How many accidents are acceptable? ZERO. How many problems are acceptable? ZERO. The goal of Case New Holland's facility is to be a zero-problem site, and World Class Manufacturing provides the map to get there. A system of continuous improvement built on a structure of 10 technical pillars, WCM serves to guide employees to focus improvement efforts using financial losses, and set priorities in major areas such as safety, quality, production, logistics, cost deployment, maintenance, environment, and people deployment. The Case New Holland Wichita facility embarked on its WCM journey several years ago.

Attend this session to learn about the “Zero Optimum” Concept and World Class Manufacturing from Humberto del Rio and Eddie Smith, both of Case New Holland's Wichita, Kan., manufacturing facility.

Key takeaways:

  • Learn how Case New Holland improved throughput by approximately 30% in its highly automated weld shop during its pursuit of the Zero Optimum Concept.
  • Gain a better understanding of World Class Manufacturing and the bottom-line impact it can deliver when applied properly.
  • See the many improvements and bottom-line financial impacts WCM has delivered for Case New Holland, even as the Wichita facility's journey continues.

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Using Kanban Systems to Drive Your Lean Strategy
Speaker:
Will Franks, President, ICON Business Associates

The best lean journeys are driven by a lean strategy supported by the appropriate tools. Although many companies think that implementing tools such as kanban systems will automatically deliver results, they are disappointed to learn that the problems exposed have overrun the results demonstrated. Results-driven successes come from implementing the right lean tools when needed, where needed -- a true just-in-time implementation approach. Under this new lean model, participants will learn what kanban systems are, why they are important, how to calculate key values such as trigger point and lot size; and they will see examples of various types of signals. Join the discussion about how kanban systems fit into and can be used to drive your overall lean strategy.

Key takeaways:

  • Learn what kanban systems are and their potential benefits to your manufacturing operation.
  • Hear real-world examples of various kanban systems.
  • Find out how to calculate key kanban system parameters.
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Applying Lean A3 Methodology for Continuous Improvement

Speaker: S. Manivannan (Mani), Manager – Global Continuous Improvement Lean Production Systems, Franklin Electric

What is A3 and how can you utilize it as a template or structured approach to develop strategies for continuous improvement? During this presentation, Franklin Electric's Subra Manivannan will review the step-by-step processes of A3 thinking and will describe how the A3 tool illustrates the meaningful and measurable results of continuous-improvement activities in a one-page management summary. His discussion will include the use and benefits of A3s in manufacturing and non-manufacturing areas.

Key takeaways:

  • Gain an understanding of how continuous-improvement strategies can be linked with A3 and quality/lean tools.
  • Learn about A3 problem-solving and Six Sigma DMAIC integration.
  • Find out how A3s can help facilitate the search for solutions to an organization's most-challenging problems.

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Quick Kaizens: Get Your Disenfranchised Employees Involved

Speaker: Bob Cortese, Controller, CTS Automotive

In today's environment, manufacturers need every employee to be a contributor. To get the commitment, companies must ensure that they have not placed any barriers in the way. Yet they do! Organizations today are very good at assigning a team to develop processes that ensure most, if not all, variables are controlled and addressed. They even use this process when developing a kaizen process. Look at a kaizen process within an organization, and there is paperwork, approvals, data gathering, filings, team assignments, network directories established, meeting schedule requirements, etc. Companies put controls and processes around the very process—kaizen—that they intend to employ to improve efficiency and eliminate non-value added tasks. So many controls are not necessary. This session is not for individuals who feel a kaizen must last three to five days and be documented prior to, during and after. It is designed to provide a path/method for the disenfranchised to get involved.

Key Takeaways:

  • WOW! Be prepared for a surprise: Kaizens are easy; there is no need for paperwork, approvals, committee oversight, facilitators or special directories to access.
  • Learn how to conduct a complete training session in less than an hour using a three-page handout.
  • Find out how to document an organization's entire kaizen process on a business card.
  • Discover a starting tool for the introverts and those put off by process complexity to step up and lead.
  • Hear how an employee suggestion program can impede an organization's goal of achieving greater efficiency.

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Bold Continuous Improvement, bold investment, bold innovation: The BMW Story
Speaker:
Mark Fendley, Continuous Improvement Manger / VPS Program Leader, BMW Manufacturing Co., LLC.

To exceed customer expectations, BMW Manufacturing must focus on the element of flexibility that comes from lean manufacturing. In this presentation, you will gain insight into how BMW can achieve the flexibility of producing millions of possible build combinations of the X3 and X5 Sports Activity Vehicles, and the X6 Sports Activity Coupe, delivering to more than 130 markets worldwide, and adhering to a pull principle of production. An overview of BMW's approach to training, good practice sharing and development for the future will be highlights of the discussion.

Key Takeaways:

  • Bold focus: determining what processes to focus your continuous improvement efforts on
  • How taking more definitive, measurable actions has resulted in bold accomplishments for BMW
  • Bold innovation: Why sustainability needs to be a part of your continuous improvement plan

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1, 2, 3 … 5S: An Easy-to-Follow Roadmap to a Successful 5S Program

Speaker: Rob Temple, Plant Manager, The Harris Products Group

Don't know where to start on your 5S plant or office program? What its benefits are? How to get employees involved? This session delivers easy-to-follow proven techniques to help guide you to a successful and sustainable program. Done right, 5S will only enhance an organization's safety and efficiencies while at the same time reducing the stress of day-to-day tasks. It is the initial transition to a fully visual workplace. What does that mean for your teams? It means a fully engaged culture ready for and open to change. 5S is a strategic seed that must be planted and promoted. It can be an easy first step on your company's lean journey.

Key Takeaways:

  • Gain a clear picture of how simple it can be to get started on your 5S program.
  • Learn how to develop an inspection and scoring program.
  • Find out how to expand your 5S program to office areas.
  • Obtain a guide to creating employee ownership of the program.
 
Advanced Continuous Improvement

Quick and Simple Simulations: A practitioner's collection of quick and simple lean simulations to engage employees and drive lean understanding
Speaker
Michael Thelen, CI Training Manager, Wells Enterprises, Inc

Ever wondered how you can get basic understanding of lean philosophy to your employees?  Perhaps wondered how to generate excitement to jump on board?  Hands-on participation and classroom presenting are great learning aides, but they don't seem to be driving home the message?  Feel bogged down with tools and techniques that still aren't helping with culture and concepts?  How about a few quick and simple simulations to help speed the learning? Get exposed to the “5S numbers” game (and see how standardized work can even be included), a fast and simple “gemba kaizen” ball-pass technique, and the ergonomic “OK” in this interactive, full-participation seminar.  Other simulations that support a variety of lean tools may also be discussed.  All simulations have been and are continuously utilized by the presenter in practical training settings.

Key takeaways:

  • Participants will participate in simple, easy-to-use and easy-to-understand simulations.
  • Through active exposure, participants will be shown how a facilitator drives learning to the workforce in either the shop or the office. 
  • Learn how interactive simulations promote better understanding of the lean philosophy.

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Awaken your Continuous Improvement System with a War Room
Speaker: Amit Mukerji, Executive Manager Quality, ABB Inc.

Does your quality system or lean efforts include a "war room?" They should. War rooms are proven tools to improve your quality system or lean efforts, and make such activities visible. A war room spotlights the "voice of the customer" as well as the "voice of the process." In this session, ABB's Amit Mukerji will share how his facility uses a war room to focus, drive and execute improvements. He will explain the process required to implement and maintain a dynamic war room. Finally, he will discuss how to use the war room as a marketing tool.

Key Takeaways:

  • Learn the anatomy of a war room
  • Find out how the war room serves as the “glue” that sustains and creates a dynamic CI process
  • Discover how a war room helps you better understand and serve your customers' needs.

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How Lean Maintenance Helps Caterpillar Improve its Remanufacturing Process
Speakers
: Mark Stratton, General Manager - Cat Reman Remanufacturing & Components Division, Caterpillar Inc.
Mark Hardesty, General Manager FMS Operations, Advanced Technology Services

In this presentation, Mark Stratton, general manager of Caterpillar's Remanufacturing & Components Division, discusses lean maintenance and how it benefits Caterpillar's remanufacturing production process. He details how employing best practices in lean production maintenance drives measureable results in production rates, reduced downtime and improved on-time delivery. Stratton also will address the critical elements necessary to develop and implement a lean maintenance process, including a discussion of key performance indicators. In addition, Mark Hardesty, operations general manager of Advanced Technology Services Factory Services, will provide insights into best practices in lean maintenance from ATS' experience with a highly diverse group of customers.

Key Takeaways:

  • Learn how lean maintenance is driving improved performances at Caterpillar.
  • Understand the critical elements necessary to develop and implement lean maintenance
  • Gain insights into developing appropriate KPIs to keep your lean maintenance program headed in the right direction.

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Obeya Operations: Tearing Down the Walls to Achieve Breakthrough Performance and Operational Excellence
Speakers: Sam MacPherson: President, The Lean Leadership Academy
Bill Levealle, General Manager, A. M. Castle Metals Aerospace
Bob Porter, Operations Manager, Timken Shiloh Plant

The Toyota Production System often is described as a biological autonomic nervous system. If that is the case, then the Obeya or “Big Room” is its brain! For first-time visitors to Toyota Motor Corp.'s headquarters in Japan and throughout the world, many are surprised to discover an operating environment without walls – the Obeya. Toyota's Obeya management process allows leaders to share timely vital information, see emerging trends through cross-departmental analysis, prioritize and coordinate efforts to maintain focus on what's important, make timely decisions, orchestrate and foster a common vision, and strive for excellence. Obeya management is the best way to achieve face-to-face communications. Toyota has established Obeya management centers for design engineering, sales and operations -- even in projects as large as the global Camry project.

In this session, presenters from Castle Metals Aerospace, Timken and The Lean Leadership Academy will share their knowledge of and successes with Obeya operations.

In addition, you will learn:

  • Overview of Toyota's Obeya operation management in sales, engineering and manufacturing
  • Obeya management and the andon system
  • Obeya leadership structure and leader standard work
  • Toyota's Obeya dispatcher, data mining and support of kaizen teams
  • Much more

Key Takeaways:
  • Hear how Timken Co.'s Shiloh Aerospace and Machine Tool Bearing Plant in Rutherfordton, N.C., uses Obeya operations, and on management and Toyota's zone control to achieve a 300% productivity increase, breakthrough performance in operational availability of equipment and quality, a 60% increase in existing capacity and daily on-time delivery to demanding customers.
  • Gain insights into Castle's Obeya operations in inside sales, logistics/traffic operations, warehouse and manufacturing operations.
  • Take home an A3 plan for Obeya operations, including a blueprint for Obeya layout.
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IW Best Plants Winners Panel: Lessons Learned on the Road to Operational Excellence
Moderator: Jill Jusko, Senior Editor, INDUSTRYWEEK 201
IW Best Plants Winners Panelists: Rob Temple, Plant Manager, Harris Products Group
David Robinson, Continuous Improvement Manager, Metal Supply Chain Manager, La-Z-Boy
Mark Hayes, Site Quality & Mission Success Manager, Lockheed Martin Missiles and Fire Control

No manufacturing facility's journey to operational excellence follows precisely the same path, as demonstrated by these representatives from three of the 2012 IndustryWeek Best Plants winners. One of the manufacturing plants represented on this panel discussion, for example, sprawls across 1.2 million square feet and builds furniture. Another engages in assembly and test of high-tech products for the defense industry. A third makes brazing and soldering consumables, doing more today with the same number of people it had in 2008 and achieving the highest quality it ever has. While all three operate in very different environments, what they share is a drive for excellence coupled with the constant challenge to build enduring cultures of continuous improvement. Learn specific practices these winning facilities employ to drive manufacturing excellence in their facilities—and come armed with plenty of your own questions!

   
Supply Chain Strategies

Vertically Integrated Manufacturing as a Long-term Business Strategy and a Way of Life at Crown Equipment
Speaker: David Beddow, VP Manufacturing Operations, Crown Equipment Corporation

Has your manufacturing company or plant been considering a move toward vertical integration? Who better to share its rewards and challenges than a manufacturer that has adopted vertical integration as a long-term strategy? Crown Equipment Corp. is one of the world's largest material handling companies. Its manufacturing processes are integral to the design and engineering of its forklifts. The company designs and manufactures up to 85% of its forklifts and components, including electric motors, drive units, electronic modules, and seats. Crown is vertically integrated across 16 global manufacturing facilities, and its approach extends throughout its distribution model of Crown-owned branches and independent dealers.

In this presentation, the speaker will share how a long-term, vertically integrated manufacturing approach can bring together every aspect of a company's production process toward the common goal of creating superior products, while meeting customer needs of quality, performance, cost and delivery.

Key Takeaways:

  • Hear advantages of vertical integration and how a long-term strategic approach can provide unique flexibility and support creative product design and engineering with the freedom to innovate and offer customized solutions in compressed timeframes – resulting in value to the customer in terms of flexibility, quality, cost and delivery.
  • Understand processes and selection criteria used to choose vertical-integration opportunities.
  • To mitigate risk of vertical integration, hear examples and considerations regarding levels of commitment, types of infrastructure and partnerships to assure manufacturing's ability to be the best long-term choice in producing components that achieve high quality and maximum flexibility at competitive costs.
  • Hear specific examples of “re-shoring” successes and other vertically integrated accomplishments that achieve stringent product engineering specifications and best value solutions, enhancing customer satisfaction.

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Extended Lean for the Total Supply Chain
Speakers: Eric Lail, Vice President Continuous Improvement, Transportation Insight
Renae Ledford, Process Engineer and Continuous Improvement Leader, Valdese Weavers, Inc.

Companies look everywhere for improvement opportunities, including beyond their four walls, but they soon realize they lack the tools or systems required to apply lean principles to this magnitude. Valdese Weavers, a jacquard fabric manufacturer, has been using lean principles to optimize its supply chain, reduce its sourcing costs and connect its value streams directly to its customers' value streams. This Extended Lean approach has enabled Valdese Weavers to thrive in North America. One of only three major manufacturers of its kind left in North America, Valdese Weavers believes that it takes a team approach to attack the tactical and strategic wastes within the supply chain to truly gain competitive advantage. Transportation Insight and its sister company, Total Insight, have partnered with Valdese Weavers to attack these supply chain wastes.

Key Takeaways:

  • Recognize the difference between a tactical approach to lean versus a strategic approach.
  • Learn how the lean journey can impact the true customer more quickly.
  • Gain a strategy for investing in your people and your lean journey.
  • Understand where the lean executive needs to focus energy to help the practitioners.
  • Learn how to increase the speed to competitive advantage.
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To Offshore or Reshore: How to Objectively Decide
Speaker:  Harry Moser, Founder, Reshoring Initiative

Recent reshorings by Apple, GE and Foxconn are causing companies to reevaluate offshoring and reshoring.  Increasingly, companies are recognizing manufacturing location's impact on innovation, time to market, inventory, IP risk, consumer preference, etc. The Reshoring Initiative's Total Cost of Ownership (TCO) Estimator software helps companies quantify these costs and 23 more. If companies make sourcing decisions based on TCO instead of price or landed cost, about 25% of what has been offshored would come back, while increasing profitability and reducing risk. 
Learn how to use the free Initiative tools:

  • TCO Estimator for sourcing decisions 
  • Case studies for free publicity about your reshoring successes
  • Library for seeking customers and competitors that are reshoring

Workforce Development

The Death of the 8-Hour Shift
Speaker
John Frehse, Chief Strategic Officer and Managing Partner, Core Practice

In a world of global competition, tightening margins and advanced technology, corporations have been slow to make aggressive adjustments to their labor strategy.  The overwhelming use of eight-hour shifts is a key sign of this lack of transformation.  As “just in time” becomes more widely adopted, the eight-hour shift will become a relic of “how we used to do it” and no longer part of the “this is how we have always done it” excuse.

Key takeaways: 

  • Learn new ways to deploy labor, including real examples of shift schedules that have been implemented successfully.
  • Learn why the current eight-hour shift may be costing your business millions of dollars.
  • Learn the pros and cons of the most common shift schedules
  • Learn what employees think about a variety of options through real benchmarking data

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Engaged Employees Drive Continuous Improvement Efforts at a Snyder's-Lance Bakery

Speakers: 
Greg Flickinger, V.P. Manufacturing and Corporate Engineering, Snyder's Lance, Inc.
Keith Mobley, Principal, Life Cycle Engineering, Inc.

Imagine a snack food plant where constant jams, breakdowns and mistakes resulted in excessive scrap, missed deliveries, loss of customers and a history of financial losses. One where the workforce had become so conditioned to the constant failures that workers approached each day with the expectation of the same frustration. Poor performance had become the accepted cultural norm. This is the situation that the new leadership faced when they assumed responsibility for the Columbus, Ga., Snyder's-Lance bakery. The challenge seemed insurmountable, but this new team, bolstered by their background in Lean Six Sigma and TPM, harnessed the resilience and ingenuity of their workforce to make historical performance improvements. For example, production lines that had run in the 55% to 65% of Tmax (theoretical maximum) range have now reliably sustained in the high 75% to 85% range without any significant capital investment. Customer service and fulfillment rates have gone from the 70% to 75% range to a stable 99%. Recordable incidents have been reduced more than 40%.This presentation will demonstrate how the team systematically transformed not simply a production plant, but also a culture.

Key takeaways:

  • Discover the power of employee engagement. The native knowledge of the workforce was leveraged to develop effective standard work for line setup and operations. The use of visual control boards and transparent performance metrics connected the employees to the resultant performance of the line.
  • Gain an understanding of the change-management methodology implemented throughout the organization.
  • Learn how the application of reliability engineering and cross-functional team problem-solving identified and resolved inherent design deficiencies.

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Need Skilled Workers? Industry and Education Initiatives that Work
Panelists:
Bryan Dods, Executive Manufacturing Technology Leader - Global Supply Chain Management, GE Energy
Werner Eikenbusch, Manager Apprenticeship & Associate Training, BMW Manufacturing Co.
Anand K. Gramopadhye, Ph.D, Assoc. Vice President for Workforce Development,  Professor & Chair - Department of Industrial Engineering, Clemson University
Susan Pretulak, Executive Director, readySC
Moderator:  Hal Johnson, President & CEO, Upstate SC Alliance

A skilled employee is a company's greatest asset. Learn how industry leaders and educators are working together to develop unique training and education initiatives to ensure companies have access to a skilled and ready workforce to meet both their current and future needs.

Key takeaways:

  • Hear examples of successful collaborations among manufacturers, educators and local organizations to develop winning models of workforce training.
  • Understand both the benefits and costs (commitment) required of industry and educators to make collaborative training initiatives succeed.
  • Learn how to get the conversation started in your community

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Achieving Excellence using High Performance Work Teams
Speakers: Brett Petrie, Senior, Director of Manufacturing, Life Technologies
Tim Dorsey, President, The Dorsey Group

Four years ago, Life Technologies' Austin, Texas, site set out to improve its performance. Realizing this is a journey and not an event, Life Technologies utilized High Performance Work Teams (HPWT) concepts launched by The Dorsey Group to transform the organizational culture. It has proven to be a journey filled with obstacles to overcome and processes to improve.

Life Technologies wanted to create a culture that would allow it to remain competitive in a very challenging and changing business environment. HPWTs is about engaging the entire workforce in challenging the way the company does business, and developing the tools, processes and structure that allow the employees to drive and sustain the results.

Life Technologies has made great progress in its journey. The Austin site has been recognized at the corporate level, receiving the Life Technologies Productivity Award. It also was named an IndustryWeek's Best Plants winner in 2011.

In this presentation, the speakers will share the roadmap, strategies and lessons learned the team experienced along the journey, as well as its continued quest for excellence. The presenters also will explore the challenges encountered at the team, department, site and corporate levels.

Key Takeaways:

  • Learn what High Performance Work Teams are and how they can help transform a culture.
  • Discover how Life Technologies implemented HPWTs at site and corporate levels.
  • Gain knowledge of tools that help actively engage employees.

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Fueling Strong Profits: Federal Heath Sign Co.'s Lean Transformation Approach
Speaker
: Rick Foreman, Director of Lean Development, Federal Heath

"Lean" thinking transformation, daily execution and the ability to sustain improvements are achieved through establishing a cross-functional lean champion team and a learning structure that engages the “why factor” and behavioral elements involving change.

Federal Heath Sign has adapted an approach that engages, connects and influences team members across all functions and levels through book studies, gemba waste engagements, learning by doing, embracing PDCA and a consistent coaching/mentoring system. This has led to a deeper, shared level of ownership and accountability, where team members consistently reflect upon what went well or did not go well today, and how to improve it tomorrow. This presentation will share a key tracking mechanism that has contributed to the ability to sustain a culture of continuous improvement while correlating directly with Federal Heath's corporate, strategic objectives. Attendees also will learn how Federal Heath identified the specific lean methodologies that best fit its organizational environments, across multiple locations.

Key Takeaways:

  • Discover how to develop a cross-functional lean champion group, within the existing leadership/management structure, that models the way for change.
  • Learn how to engage, connect and influence team members, with lean thinking and problem solving, across all functions, through lean coaching and mentoring at the gemba.
  • Learn how to gain and sustain buy-in for change at the individual, team, organization, customer and enterprise level.
  • Gain a deeper understanding about how to execute a lean transformation, across multiple facilities, while overcoming past management philosophies, geographical influences and past improvement failures.

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Strategic Training at Siemens Energy
Speaker
: Pamela B. Howze, SPHR, Training and Development Manager, Siemens Energy

Attend this session and learn how Siemens Energy Inc. takes a strategic and holistic approach to workforce development through its employees, collaborative community partnerships with educational institutions and other businesses. In addition, Siemens has created an operational Train the Trainer program using subject matter experts from across the campus. Learn how Siemens started a formal European-type apprenticeship training program for young adults while they are still attending high school and a maintenance apprenticeship program for veterans exiting the military. Siemens also has deployed ToolingU across the site, giving all operators equal access to training regardless of what shift they work, via strategically placed eLearning stations on the manufacturing floor. This session will address:

  • Technical Training Development for New Gas Turbine Plant
  • Safety Training Program
  • Train the Trainer Program
  • Apprenticeship Program
  • eLearning Through ToolingU
  • STEMersion
 
Leadership & Innovation
The Lean Leadership Roadmap: A New Blueprint for Developing Highly Engaged Lean Leaders
Speakers
: Sam MacPherson, President, Lean Leadership Academy
Art Smalley, President, Art of Lean, Inc.

What happens when you combine leadership development secrets of the world's greatest manufacturer with the world's most elite military unit?

Toyota is without question one of the most successful and studied companies in the world. Yet, despite the volumes of books, articles, case studies and countless benchmarking tours, few organizations have been able to match Toyota's performance, profitable growth and culture of engagement. 

Similarly, the U.S. Army Special Forces' (or Green Berets') elite training, team-based culture and legacy of excellence produce leaders capable of acting as the front line of American diplomacy in the most remote regions of the world -- winning hearts and minds, and reaching the highest levels of service to the United States. 

In this session, lean leadership experts Art Smalley (Toyota Motor Corp., Donnelly Corp., McKinsey and Co., Art of Lean) and Sam MacPherson (former chief of training, U.S. Army Special Forces Command, award- winning lean manufacturing senior executive) take you inside the Green Berets and inside Toyota. Smalley and MacPherson will share their solution to America's manufacturing and industrial leadership gap and their blueprint for developing a legacy of highly engaged, organizational lean leaders that will create bench-strength depth, critical mass and breakthrough performance.

Here is some of what you will learn:

  • Lean's Greatest Need: The willingness and ability to lead
  • Lean vs. TPS (Toyota Production System): organizational lean compliance vs. the True Aims of TPS
  • U.S. Army Special Forces and Toyota: A comparative case study about how these two organizations develop a legacy of successful leaders
  • How Toyota and the Green Berets are organized to succeed through small group leadership and the deployment of organizational problem-solving capability
  • The Attributes of a Lean Leader
  • 10 keys to creating a legacy of lean leaders dedicated to operational excellence and people engagement

Key takeaways:

  • A3 of Lean Leadership Academy approach and model
  • A blueprint for developing systematic current and future organizational lean leaders capable of leading in a Toyota Production System/Toyota Management System environment
  • Example of lean leadership development training plan overview

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Developing Lean Leaders at IBM's Advanced Microelectronics Solutions
Speaker: Patrick Varekamp, Senior Technical Staff Member – Microelectronics Division, IBM

It is often a challenge to transform leadership to truly understand, think and behave lean. In this session, you will learn about a structured and repeatable activity for improving the discipline of lean leaders—an approach that is flexible enough to be applied to any organization and at any management level. Patrick Varekamp, senior technical staff member in IBM's Microelectronics Division, will present results from the structured approach and discuss the critical success factors learned from applying the approach to the senior leadership team of IBM's Advanced Microelectronics Solutions organization.

Key Takeaways:

  • Learn how to assess which lean behaviors exhibited by your leadership team are holding back your organization's lean transformation.
  • Understand the details of a structured and repeatable method to transform your leadership team into disciplined lean leaders.
  • Identify lessons learned from the application of this method to a team of executives in IBM's Advanced Microelectronics Solutions organization.
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From Plant Managers to Profitability Engineers: Meeting the Needs of Today's Global Economy with Business-Savvy Plant Managers
Speaker: Susan Nutson, SVP Human Resources, Saint-Gobain North America

In today's fast-paced and global economy, the role of plant manager is evolving at breakneck speed. Plant managers who are technically savvy yet are also financially literate with a strong business sense are becoming the new standard. Identifying and building a talent pool of managers who are aware of the marketplace and how the plant manager can position the plant for an economic advantage while also ensuring smooth and efficient production brings a whole new level of complexity for those responsible for talent acquisition and growth.

Attend this session to learn about Saint-Gobain's global and North American-specific approach to growing and identifying Profitability Engineers.

Key takeaways:

  • Learn how the role of plant manager has shifted over time and how your company can seek to meet the needs of this evolving field.
  • Gain insight into the skill sets needed from this new generation of plant managers.
  • Learn from Saint-Gobain's first-hand experience in growing and acquiring this new type of plant manager.
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Adapting the Toyota Product Development System
Speaker: Bob Melvin, Vice President of Engineering, Teledyne Benthos, Inc.

Test first, then design': How to turn the traditional product development process on its head -- and

  • learn what you don't know early on in a project,
  • eliminate the dreaded “loop-back,” ensure that new products hit the sweet spot: the right technology at the right price at the right time, and
  • achieve a steady -- and faster -- pace of new product development.
Sound impossible? This Teledyne Benthos presentation shows you how.

Key Takeaways:

  • how to develop a knowledge library to establish a reliable ‘corporate memory'
  • how to change engineering's propensity to start designing immediately thus eliminating  the dreaded project loopbacks
  • how to develop a new product development rhythm embraced by both engineering and sales
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Warren Rupp Tackles Material Flow Optimization to Pump Up Productivity

Speaker: William Jones, Vice President of Operations, East Asia, IDEX Corporation
John Carter – President Diaphragm & Dosing Pump Technology, IDEX Corporation

Warren Rupp will take you through the process it employed to successfully implement a plantwide Material Flow Optimization (MFO) project in a manufacturing environment. During this session you will learn how Warren Rupp's Mansfield, Ohio, plant, a 2012 IW Best Plants winner, redesigned an entire plant in order to improve the flow of materials and effectively manufacture and ship product out at a faster pace. How successful has the project been? The plant hit its ROI target in three months, a full year ahead of expectations.

Key Takeaways:

  • Find out why Warren Rupp took on this project. What issues was the company trying to solve?
  • Learn about the methodology Warren Rupp used to ensure an on-time, successful project completion
  • Understand how to effectively get buy in from all levels of the corporation.
  • Hear about the challenges Warren Rupp faced along the way.
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Natural Capitalism Through Innovation

Speaker: John Bradford, Chief Innovations Officer, Interface America's Inc.

This presentation examines past attempts to leverage nature in our economic systems and the vectors that are destined for failure. History shows that it is impossible to thwart the natural process, and while technology can sometimes delay consequences, it cannot eliminate them. An introduction to biomimicry drives the point home that our world evolved over the last 4 billion years and will continue to evolve, despite humankind's best efforts to destroy it. With Nature as the instructor, observe how humans can become a part of nature, rather than moving away from nature. Interface Chief Innovations Officer John Bradford will explore ideas on how to transform the economic system to one that is more sustainable, bring thoughts into action and set up the story of specific projects that have had meaning in the transformation of Interface, a carpet company aspiring to become a sustainable enterprise by the year 2020.

Key Takeaways:

  • Not all good intentions have a positive effect on our economic system's balance and resilience.
  • History shaped current assumptions surrounding our economic system
  • Introduction to biomimicry, highlighting the contrast between an “evolved” planet over one that is “created”
  • Role of Nature as a teacher
  • Transforming our economic system to a more sustainable enterprise/world
   
Manufacturing Technology Strategies

Manufacturing Visibility & Productivity at Toyota
Speaker: 
Trever White, Information Systems Manager - Manufacturing & Quality Business Systems,
Toyota Motor Engineering & Manufacturing, North America
 
Toyota has always believed in a “Go and See” philosophy in manufacturing to make informed decisions with the best information available. Their efforts to implement a multi-site strategy to integrate production, maintenance and quality systems with their enterprise is an ongoing, strategic initiative within Toyota, and one that has brought the Information Systems (IS) group much closer to the plants they support. Join Trever White, IS Leader – Manufacturing & Quality Business Systems, Toyota North America, for an open, interactive discussion on what they have learned on their journey toward enterprise-wide manufacturing visibility, why they're doing it, and how they're making it happen.

Key Takeaways:

  • The value of manufacturing visibility to drive productivity
  • The need for cross-functional business collaboration between plants and corporate groups
  • The key challenges, lessons learned and best practices Toyota has uncovered on their journey

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How Reynolds American Transformed its Business – An End-to-End Transformation Journey Linking People, Processes and Technology
Speakers: 
Missy Moore, Senior Director Information Management, RAI Services Co.
John Southcott, Co CEO, Brock Solutions
 
Learn from Missy Moore as she shares the challenges R.J. Reynolds faced -- a shrinking market, increasing taxes, obsolete infrastructure, and an aging workforce with decades of knowledge walking out the door -- and the call to action to transform the business.  R.J. Reynolds' transformation began with the development of a five-year manufacturing strategy, coupled with leadership's commitment to build a high-performance culture and enabled by the appropriate technology boost. This session will detail how R.J. Reynolds tackled its challenges and emerged more efficient and profitable than before.

Key takeaways:

  • Discover the lessons learned by R.J. Reynolds as it pursued its transformational program – learn what to do and what not to do.
  • Gain a clear picture of the technology and implementation steps required to enable such a transformation.
  • Hear specific quantitative and qualitative achievements the transformation delivered.

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Driving Continuous Improvement through Workflow Automation
Speakers:
Rusty Callier, Director of Operations, Uponor
Mike Stuedemann, Engagement Manager, Savigent Software

A pillar of manufacturer Uponor's strategy for operational excellence is its focus on continuous improvement to increase product quality, improve manufacturing efficiencies and reduce operating costs. This presentation provides an overview of the continuous improvement strategy of Uponor, an international provider of plumbing and indoor climate systems for the residential and commercial building markets. The overview will include a special focus on the company's lean manufacturing initiatives and Six Sigma efforts. In addition, two case studies will provide detailed insight into continuous improvement at Uponor's North American manufacturing facility. One case study documents Uponor's efforts to improve asset availability and utilization within its large installed base of plastics extruders – part of its effort to improve overall equipment effectiveness (OEE). A second case study focuses on the role workflow automation (business process management) plays in driving responses to actionable events and their ability to change behavior on the plant floor.

Key Takeaways:

  • Discover actions you can take to improve equipment availability and utilization.
  • Gain an appreciation of the role behavior change and data-driven decision-making play in the success of continuous-improvement initiatives.
  • Learn how an increased focus on the incidents (exception events) that impact efficient, effective and economical manufacturing drives change in an operation.
  • Increase your understanding of workflow automation and its application to drive continuous improvement in manufacturing operations.
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Manufacturing Technology Evolution at Mondelēz International

Speaker: Erik Nistad, Director, Enterprise Business Services, Integrated Supply Chain, Mondelēz International

For many years, corporations have realized the value of standardized systems across the enterprise level for driving consistency, simplicity and efficiency. In recent years, companies have turned their eyes toward the plant floor attempting to extend those benefits all the way to production. Come hear how one large global manufacturer has begun that journey and the pitfalls it encountered along the way. Learn how you can leverage its experiences to extend those benefits to your organization.

Key Takeaways:

  • Approach to aligning organizations across functions and the globe on manufacturing systems strategy
  • Leveraging standardization to capture and drive information from manufacturing automation to ERP
  • Developing and aligning an approach for integrating both the “old” and the “new”
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Pre-Conference Workshops

Cellular-Flow
Monday, April 22 - 8:30 am – 11:00 am  Additional fee to attend.
Instructor:  Jim Woody, Technical Specialist, South Carolina Manufacturing Extension Partnership

I. The Basics of Lean Quick Review

  • Definition
  • Value Added vs Non Value Added
  • 8 Wastes

II. The Value of Time

  • Cash Flow
  • $ Value of Cost

III. Tying in Lean Concepts with Flow of the Product

  • Impact of Inventory to Flow of the Product
  • Impact of Balance to Flow of the Product
  • Basic Considerations in Cellular Flow
  • Calculating Optimum Inventory in a Cell

IV. Managing Differently in a Lean Environment

  • Process Lead Time
  • A Realistic Measure of Productivity - Breaking a Paradigm
  • Key Measures to Use in Managing a Workcell
   
Training Within Industry (TWI)
Monday, April 22 - 1:30 pm – 4:00 pm  Additional fee to attend.
Instructor:  Susan Whitehead, Technical Specialist, South Carolina Manufacturing Extension Partnership

TWI was developed in the United States during WWII to train replacements for an industrial workforce who left to fight a war.  It was very successful and is credited with helping the United States out-produce the enemy.  After the war, our experienced workforce returned home.  TWI was just a memory in the United States, but we taught it to other countries who have been using it ever since. Now it's back! Competition and has forced us to look for more help.  TWI has been called the missing link. It creates the culture to sustain our lean improvements.   It's a return to foundational tools and so much more!
 
Learn how to implement the three modules of TWI.

Job Relations:  Build a culture of cooperation and respect, where employees and supervisors have strong relationships enabling them to develop their own skills as well as continually improve processes.  Teach lead people and supervisors Foundations for Good Relations to help prevent problems along with a 4 step method to deal with people problems when they arise.

Job Instruction Build a culture where your most skilled employees know how to share their knowledge with other employees.  Teach them to efficiently bring others up-to-speed so more and more employees can execute work consistently. This creates a strong teamwork culture between employees at many levels. (Wouldn't you trust someone who taught you a valuable skill efficiently and effectively?).

Job Methods:  Teach lead people and supervisors to work with employees to review work processes and create continuous improvement. You don't have to wait for a team event. We want all employees looking for better ways to do the work every day. Job Methods teaches a method for coming up with improvement ideas and creating a concise proposal to present to management. 

 
MESA International Business Forum
(open to IW Best Plants Conference attendees, part of co-located MESA's 2013 North American Conference)
Monday, April 22 - 9:00 am – 12:00 pm

Join the MESA International Business Forum to kick off the conference.  Meet the MESA International president, board of directors and fellow industry professionals.  You're invited to participate in MESA's International Board meeting from 9-10:30am.  Or join us at 10:30am to learn about recent MESA accomplishments and future objectives.  Dive into the MESA Global Education Program (GEP) and on-going strategic initiatives.  And, champion your own cause by telling MESA leaders what you need from the association to deliver on-going value in your organization. Limited seating available.

 
MESA unConferences: Open Forums on Making Your Plants Operate Best
(open to IW Best Plants Conference attendees,
part of co-located MESA's 2013 North American Conference)

Monday, April 22 – 1:00 pm – 2:30 pm
The Value of Manufacturing Technologies in Continuous Improvement
OR
ROI & Justification for Manufacturing IT Solutions

3:00 pm – 4:30 pm
Improving Manufacturing Performance so Executives Notice
OR
Your Voice: What tools, technologies, education and capabilities you and your business need to thrive.

Forget the lectures, let's roll up our sleeves!  MESA International is bringing their “unConference” format to Greenville to offer you a safe, open environment to address your most pressing challenges.  These sessions offer a rich, interactive environment in which knowledge sharing works best.

No presentations or speakers here, in a MESA unConference, you set the agenda.  Choose which themed unConference you'd like to attend and bring all your burning challenges.  Experienced MESA professionals will moderate the discussions between you and your peers, encouraging all to contribute to the sharing of ideas and lessons learned.

 
Building a Sustainable Safety System
How Milliken Built a Culture of Safety Excellence Through Engagement
Monday, April 22 - 1:30 pm – 4:00 pm  Additional fee to attend.

Instructors: Chris Glover, Director - Milliken Performance System, Milliken & Co.
Phil McIntyre, Director Business Development and Marketing - Milliken Performance Solutions, Milliken & Co.

Through numerous real-world Milliken examples, you will be able to understand the fundamental beliefs and strategies behind a successful World-Class Safety operation. You'll learn how to:

  • Create a ‘Bottom-Up Approach' that facilitates associate empowerment, ownership, and engagement
  • Understand how Leadership and Team Development play an integral role in your safety journey and your Culture
  • Obtain Leadership commitment and desire and how Safety should be the ‘Core Value' of your organization
  • Create, train, and educate sub-committees based on your particular environment and needs
  • Avoid reaching a safety plateau and how to keep driving continuous improvement

Workshop outline:

I. The 9 Immutable Keys to a Successful and Sustainable Safety Process

  • The aspects of Leadership Commitment
  • What role does ‘Culture' play?
  • How to incorporate the right metrics at the right time.
  • Training, Education, Audits, Code & Compliance all part of a ‘holistic' safety process. Tools are not Enough!

II. The Milliken Safety Process

  • Safety as the ‘Trust' factor
  • How to develop a culture of associate engagement and empowerment
  • Selecting a Steering Committee
  • Selecting the proper Sub-Committees
  • How associate-led safety teams and committees create the culture whereby improvements are sustainable

III. Financial Benefits

  • The financial benefits of being ‘Safe'

Milliken & Company is a 147 year old textile and chemical company based in South Carolina that has been internationally recognized for its achievements in safety and operational excellence. With safety as its #1 core value, Milliken has 29 OSHA certified Voluntary Protection Program (VPP) STAR sites and is one of the few organizations to have its headquarters—Roger Milliken Center in Spartanburg, SC—that has become an OSHA certified Voluntary Protection Program (VPP) STAR site.

Milliken's Safety Process is a proven, 20-step process that engages the entire workforce. Driven by the desire to eliminate ALL safety incidents, this proprietary process has been developed over the past decade through benchmarking best practices around the world and actively engaging and empowering the entire workforce. While Milliken & Company has been recognized as a benchmark in safety, the goal still remains ZERO.

Milliken's Safety Process is a comprehensive system that leads to dramatic breakthroughs in employee safety, motivation and morale, and overall cost reduction. It is all about cultural and systems changes and not just about the application of tools. This process applies to all types of businesses from manufacturing to public and private industry. It is about changing the way employees go about doing their job, not bolting on safety initiatives that are not sustainable over the long term.

Milliken's Safety Process is an employee-centric approach to improving safety that is designed to build an organic, internal capability that is permanently infused into the organization. Milliken has been recognized repeatedly by organizations such as Occupational Hazards magazine as one of the safest companies in the U.S., regardless of industry. Milliken is the only American company that has won the top manufacturing award in both the United States and Japan — the Malcolm Baldrige National Quality Award in the U.S. and the TPM Excellence Award sponsored by the Japan Institute of Plant Maintenance. In addition, Milliken has been named five times as one of the Best Companies to Work For inFORTUNE Magazine's annual top 100 listing. The company has also been named one of the World's Most Ethical Companies by Ethisphere Magazine.

 
Lean Product Development
Monday, April 22 - 1:30 pm – 4:00 pm  Additional fee to attend.
Instructor:  Chris Wayne, Growth Services Manager, South Carolina Manufacturing Extension Partnership

If your company is like most, the transition of new products from engineering to manufacturing is difficult and inefficient.
 
Help streamline the flow of new products from engineering through manufacturing. Reduce wasted time, energy and resources. Improve communication and teamwork. Companies that use Lean Product Development techniques reduce time to market by up to 70%, and reduce development costs by over 30%.
 
Topics include:

  • Visual project boards
  • Stand-up coordination meetings
  • Lean Product Development Process Flow
 
How and Why to be an IW Best Plants Winner
Monday, April 22 - 2:30 pm – 3:30 pm 
Instructor:  Jill Jusko, Senior Editor and IW Best Plants Awards Coordinator, IndustryWeek

The IndustryWeek Best Plants Awards program annually salutes North American manufacturing excellence. During this session, IW Best Plants awards coordinator Jill Jusko discusses the IW Best Plants competition process and walks you through the IW Best Plants application. She will highlight key questions and provide insights into performances achieved by past participants. Audience questions will be encouraged throughout the presentation.

 

 

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Congratulations to our 2012 IW Best Plants winners:


CNH Wichita Product Center

Wichita, Kan.

Ethicon LLC

San Lorenzo, Puerto Rico

Harris Products Group, a Lincoln Electric Co
.

Mason, Ohio

La-Z-Boy Tennessee

Dayton, Tenn.

Lockheed Martin Missiles and Fire Control, Pike County Operations

Troy, Ala.

Warren Rupp Inc.

Mansfield, Ohio 

Click on a link to read their story.  Hear their best practices at the conference.

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