Joe Buonodono

Johnson Controls Inc. CI Manager, Business Process Improvement

Adding Enterprise-Wide Value to Your Organization

Organizations can gain a competitive advantage through better engineering, better innovation and through faster, more effective problem resolution and continuous improvement efforts. By focusing on the latter, Johnson Controls

has saved millions of dollars. The catalyst is building capability in your people.

Discussion Outline

Introduction of JCI

JCI approach to building capability in its people

• Leadership Institute training • KT Practitioners • Triple certification

Case studies Tangible Results Questions

Approximately 150,000 employees worldwide Three main businesses: Building Efficiency, Automotive Experience and

Power Solutions

Brief Background of Johnson Controls

Johnson Controls celebrates 125 years of making buildings more energy-efficient for

its customers. The company was founded in 1885 by Professor Warren Johnson

following his invention of the first electric room thermostat. The invention launched an industry dedicated to energy efficiency,

through the regulation of temperature room-by-room in homes and commercial

buildings.

JCMS Path to Operational Excellence

Integrate into Daily Work

Control

Improve

Analyze

Measure

Define

Recognize

Brief Background of Johnson Controls

The KT Rational processes and icons

JCI’s approach utilizing KT: Educate And reinforce capability

KT Rational Processes Removal of Special Cause

Situation Appraisal (SA)

Problem Analysis (PA)

Potential Problem Analysis (PPA)

Lean Removal of Waste

Six Sigma Removal of Common Cause

KT Continuous

Improvement Prioritization & Resource

Assignment

Situation Appraisal (SA)

Decision Analysis (DA)

Potential Problem Analysis (PPA)

Potential Opportunity Analysis (POA)

Brief explanation of Triple Certification

JCMS

We communicated KT throughout the company and its importance to individual development

Internally created website for information, training, & knowledge

Training

Execution

Results

We have systems that measure not “just” training, but execution and results

Learning Management System

Projects in CI Trac

$, Quality, Safety, etc in CI Trac

We created the “Practitioner Certification”

The landscape of training and certification

# of people trained

# of projects completed

Needles moved

This was the line in the past

Three Steps to Kepner-Tregoe Practitioner Certification

M.C. attended KT training recently, and used the PSDM tools on a new launch problem that occurred at her plant shortly afterward. The total savings for the project are over $60,000, and it is a very

good example of the application of the tools

JCIM Southview Facility Application

Definition of the problem

The problem was a new launch product. It was a vehicle door panel that had a thin foam strip around the back of the part.

The defect was that the foam was peeling away from the door panel

Result:

Additional Labor

Additional Time

Added Material cost

To try and reduce the effects, a separate station was put in place. Additional foam was being placed over the corners to try and keep the foam down

Specification and Identifying Cause

Because this was a NEW LAUNCH, the IS-NOT was developed by finding another

closely related product

M.C. used Distinctions and changes to uncover some key differences between

her door panel and the IS NOT door panel

Determine Most Probable Cause, Verify

The adhesive on the foam was discovered to be incompatible with the lamination process used on this door.

A better, lean solution was to use a different adhesive, that in addition to being less expensive, allowed the team to apply the perimeter foam within the cycle time of an existing assembly process.

Case example using KT during Lean Event

P. M. in his plant after Kaizen

P.M. used the PSDM tools to bring several improvements together, and he used DA to help select a new layout for his improved line.

P.M. using the DA with Lean

Not all decisions have to “hit” paper, but making the thinking visible helps drive team consensus, in this case the team did use the KT template

Value beyond financial measures…

S. C. $28,000 savings from KT Projects

S.B. $28,000 savings from KT Projects

Additional examples Vinyl defects on Door Panel program

Seat Travel sensor

Vinyl adhesion for OEM PAB Sonic Welded component

Questions / Comments

Sam Bernstine Automotive Practice Leader

Kepner-Tregoe, Inc.

Joe Buonodono

Johnson Controls Inc. CI Manager, Business Process Improvement

SBernstine@kepner-tregoe.com

Joseph.b.buonodono@jci.com

Office: +1/ 609-252-2417

Mobile: +1/ 724-944-9169