cme kaizen conference 2014 – leading lean transformation...

Your Ideas, Our Solutions.

CME Kaizen Conference 2014 – LEADING LEAN TRANSFORMATION

© 2014 Tony Kerwin

LEADING LEAN

TRANSFORMATION

Tony Kerwin, P.Eng. Chief Operating Officer

Acrylon Plastics Inc. Winnipeg, Manitoba, Canada

February 20, 2014



© 2014 Tony Kerwin

Acrylon Overview

Your Ideas, Our

Solutions

• 6 Facilities – SK, MB, Minnesota – HQ in Winnipeg, MB

• Over 300 people • ISO9001 Registered since 2002 • 45+ years in the plastics business • Over 30 years design engineering

experience • Multiple quality test labs • In-house jig/fixture

manufacturing • Complex assembly capability

• Color mixing capability • Data pack in-mold heat

monitoring • Extrusion Die making capability • Gel test capability • 23 rotomolding machines

– Up to 4500 pound capacity

• 5 vacuum forming machines • 8 single screw extruders • 16 twin screw extruders • 9 CNC trimming machines



© 2014 Tony Kerwin

Passionate People Forming Creative Solutions We will: Partner with selected leading Customers and Suppliers, earning their long-term loyalty.

Effectively deploy a safety culture and continuous improvement.

Pledge to our passionate team members a consistent, transparent and knowledgeable workplace.

Encourage a culture of engagement and respect through active communication.

We will act ethically at all times.

We will conduct ourselves responsibly within our community

Maximize long-term Customer and Shareholder value.



© 2014 Tony Kerwin

Core Values

We trust our coworkers and treat each other with mutual respect and honesty.

We work in an open, transparent, thoughtful culture.

We take pride in our diversity.

We are passionate about our growth opportunities and participating in the success of all of our stakeholders.

We act ethically at all times. We actively support our local communities and conduct ourselves responsibly within

them.



© 2014 Tony Kerwin

Henshaw Award for Corporate Leadership in

Safety

IAPA PRESIDENT’S SAFETY AWARD



© 2014 Tony Kerwin

• Ensure ALL Actions are Legal, Ethical & Moral • Actively Participate and Communicate Openly • Sign Your Work With Personal Pride • Focus Passionately on Waste Elimination • Aim for Excellence & Perfection • Treat Others With Dignity & Respect • Strive to Make a Difference Every Day • Lead With Your Heart as Well as Your Head • Follow Through on Your Commitments • Always Spell Customer with a Capital “C” • Be committed to the betterment of the team • Play to Win Every Day – Don’t Compromise

People Expectations



© 2014 Tony Kerwin

• Deal With Facts not Opinions • Maintain Confidentiality • Do Not Engage in Rumour Mills • Be Professional in All Activities • Be a Role Model for All Employees • Once a Decision has been made, Support it 100% • Be Responsible and Accountable for Your Actions • Engage in Proactive Performance Management • Be a Team Player • Support the Other Leaders – Do Not Criticize

Leadership Expectations



© 2014 Tony Kerwin

Pseudo Team

High Performing Team

perf

orm

ance

team effectiveness

Work Group

Potential Team

Real Team

Source: Katzenbach and Smith - The Wisdom of Teams



© 2014 Tony Kerwin

FMEA SMED

KANBAN

EPEI

TPM

FLOW

POINT OF USE

5S POKA -YOKE STD

WORK VSM DMAIC

SPC

5 WHY

KAIZEN

DOE

FMEA

TWI

V of C Cp

CpK



© 2014 Tony Kerwin

Customers (The Designer)

External Focus

C A P A B I L I T I E S

Inventory

Lead Time

Quality

Cost

Service

Product Development

Sustainable

P R O C E S S



© 2014 Tony Kerwin

EHS

Quality

Throughput Profit



© 2014 Tony Kerwin

THINK SMALL. Small changes rather than big changes.



© 2014 Tony Kerwin

改 ("to change") + 善 ("good")

KAIZEN



© 2014 Tony Kerwin

Kaizen Activity

0

50

100

150

200

250

300

350

400

450

Octobe

r

Novem

ber

Decem

ber

Janu

ary

Februa

ryMarc

hApri

lMay

June Ju

ly

Augus

t

Septem

ber

YTD Target

YTD Actual



© 2014 Tony Kerwin

Kaizen Activity



© 2014 Tony Kerwin

Manufacturing Lead Time

0

10

20

30

40

50

60

70

80

01-J

an-0

201

-Mar

-02

01-M

ay-0

201

-Jul

-02

01-S

ep-0

201

-Nov

-02

01-J

an-0

301

-Mar

-03

01-M

ay-0

301

-Jul

-03

01-S

ep-0

301

-Nov

-03

01-J

an-0

401

-Mar

-04

01-M

ay-0

401

-Jul

-04

01-S

ep-0

401

-Nov

-04

01-J

an-0

501

-Mar

-05

01-M

ay-0

501

-Jul

-05

01-S

ep-0

501

-Nov

-05

01-J

an-0

601

-Mar

-06

5/1/

2006

7/1/

2006

01-S

ep-0

601

-Nov

-06

01-J

an-0

7

82% Reduction



© 2014 Tony Kerwin

ON TIME DELIVERY PERFORMANCE

0%10%20%30%40%50%60%70%80%90%

100%

1996 1997 1998 1999 2000 2001 2002 2003

TARGET

REDEFINITION OF OTD



© 2014 Tony Kerwin

INVENTORY TURNS

0

5

10

15

20

25

30

May-00

Jul-0

0

Sep-00

Nov-00

Jan-01

Mar-01

May-01

Jul-0

1

Sep-01

Nov-01

Jan-02

Mar-02

May-02

Jul-0

2

Sep-02

Nov-02

Jan-03

Mar-03

May-03

Jul-0

3

TARGET



© 2014 Tony Kerwin

QUOTE TURNAROUND PERFORMANCE

0

5

10

15

20

25

1999 AVG

2000 AVG

01/0102/01

03/0104/01

05/0106/01

07/0108/01

09/0110/01

11/0112/01

01/0202/02

03/0204/02

05/0206/02

07/0208/02

09/0210/02

11/0212/02

01/0302/03

03/0304/03

05/0306/03

07/0308/03

DA

YS

TARGET



© 2014 Tony Kerwin

52% reduction in internal defects to 22 PPM

100% reduction in Customer rejects to 0 PPM

Reduced Class A supplier lead time by 30%

Improved Asset Turnover by 10%

Reduced cycle time by 76%

Reduced order-to-delivery lead-time by 36.8%

Reduced Raw Material Inventory by 25%

Reduced WIP by 80%

50% Improvement in First-Time-Yield



© 2014 Tony Kerwin

LEADING LEAN

TRANSFORMATION

Tony Kerwin, P.Eng. Chief Operating Officer

Acrylon Plastics Inc. Winnipeg, Manitoba, Canada

February 20, 2014

cme kaizen conference 2014 – leading lean transformation...

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