2008 Crystal Award Winner

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Winner of the 2008 Crystal Award for most Innovative Door plant in America Plant Manager Ron Baroni

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2008 Crystal Award Winner

  1. 1. Welcome to the Champion Door Division’s New Culture & Facility Winner of the Most Innovative Small Manufacturing Plant in the US. Crystal Award
  2. 2. New Facility & Culture <ul><li>The Company has committed 1 million dollars plus over two year period to help the Door Division increase Capacity and improve Speed thru the Facility thus reducing lead-times . </li></ul><ul><li>The new facility was Developed & Launched to Market Champion Door’s Pride in Manufacturing thru High Quality Products, Speed thru the Facility, Outstanding Housekeeping and New Management Culture. </li></ul><ul><li>The new facility provides Associates to take Ownership of their Work Cell. This Ownership translate into their taking responsibility for “building in “High Quality Work” vs Inspecting it in”, Maintenance of their Equipment, & Conformance to our Responsible Expectancies. </li></ul>
  3. 3. New Facility & Culture <ul><li>The Manufacturing Processes have been developed around the latest Manufacturing Techniques used by some of the most progressive Companies in the United States and Japan. Techniques such as: </li></ul><ul><ul><li>Lean Manufacturing </li></ul></ul><ul><ul><li>Value Stream Planning & Mapping </li></ul></ul><ul><ul><li>5S Program </li></ul></ul><ul><ul><li>Kaizen </li></ul></ul><ul><ul><li>Focused & Visual Factory </li></ul></ul><ul><ul><li>Kanban </li></ul></ul><ul><ul><li>Fool Proofing </li></ul></ul><ul><ul><li>Failure Mode & Effect Analysis (FMEA) </li></ul></ul><ul><ul><li>TPM </li></ul></ul>
  4. 4. New Facility & Culture <ul><li>The New Facility was Designed to: </li></ul><ul><ul><li>Increase Manufacturing space from 22,000 sq ft to 50,000 sqft. </li></ul></ul><ul><ul><li>Produce 50 Orders per day vs 23 Orders on a single shift. </li></ul></ul><ul><ul><li>Provide for a separate Shipping and Receiving dock to facilitate future growth of dedicated Door Trucks for deliveries to Affiliates. </li></ul></ul><ul><ul><li>Improve lighting in the facility from 28 ft candles to 107 ft candles allowing Manufacturing personal to Improve Outgoing Quality. </li></ul></ul><ul><ul><li>Provide for flexible electrical drops to facilitate movement of equipment for future process improvements and cost reductions. </li></ul></ul><ul><ul><li>Provide for Bulk Storage along only the facility perimeter vs in-process for ease of material movement and elimination of in-process aisle ways allowing more space for manufacturing equipment. </li></ul></ul>
  5. 5. New Facility & Culture <ul><li>The New Facility was Designed to (con’t): </li></ul><ul><ul><li>Provide True Cellular Manufacturing Cells coupled with Ergonomic design to promote High Quality, Quick thru-put and Associate Ownership of their Cell. </li></ul></ul><ul><ul><li>Promote Hourly & Salary Associate Pride in Manufacturing by eliminate all supplemental janitorial support and demanding a “pick up after yourself” + “Keep it Clean” environment thru out the facility. </li></ul></ul><ul><ul><li>Eliminate all Bells and Buzzers. Atomic clocks are positioned thru out the facility to ensure all the clocks are at the “same” time. </li></ul></ul><ul><ul><li>To eliminate the need to leave their Cells early & run upfront to the time clock to be first out. All Associates check in (before the shift) and out (after the shift) at the center of the facility. </li></ul></ul><ul><ul><li>Provide additional Assembly Capacity for Single & Multi-panel Orders via additional new equipment. </li></ul></ul>
  6. 6. New Facility & Culture <ul><li>The New Facility was Designed to (con’t): </li></ul><ul><ul><li>Provide a new Coating Process to improve Quality and increase Capacity by 43% on a one shift operation: </li></ul></ul><ul><ul><ul><li>Powered Conveyor System that operates at 7.2 ft per minute to improve productivity. </li></ul></ul></ul><ul><ul><li>Providing a new Coating Process to improve Quality and increase Capacity by 43% on a one shift operation (con’t): </li></ul></ul><ul><ul><ul><li>Fifteen parts carriers to provide easy access on all sides of materials to be coated. </li></ul></ul></ul><ul><ul><ul><li>Enclosed side-downdraft Pressurized Spray Booth to reduce dust on components during Coating and provides a clean environment for coating products vs the old open non pressurized paint booth. </li></ul></ul></ul><ul><ul><ul><li>A 12 color Coating Changer (expandable to 24) that allows us to go to 1 of any 12 colors in about 30 seconds. </li></ul></ul></ul><ul><ul><ul><li>Enclosed and Pressurized flash off tunnel and IR (80- Halogen Emitters) Oven that reduces dust on the parts and fully cures the coating in less than 5 minutes vs 45 minutes to an hour (to the touch) and 72 hours fully cured. </li></ul></ul></ul>
  7. 7. New Facility & Culture <ul><li>The New Facility was Designed to (con’t): </li></ul><ul><ul><ul><li>Enclosed Coating Kitchen: </li></ul></ul></ul><ul><ul><ul><ul><li>12 Colored Coatings purchased in 5 gal vs 1 gal containers providing a Cost reduction on Coating materials. </li></ul></ul></ul></ul><ul><ul><ul><ul><li>White Coating purchased in 55 gal drums vs 5 gal pails providing Cost Reductions. </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Continuous mixing, on demand availability of 13 colors for Spraying vs selecting each gal, mixing it, spraying, cleanup & put away of the coating materials. </li></ul></ul></ul></ul><ul><ul><ul><li>Provides a coating surface that is extremely hard preventing most scratching during the Assembly Process and during transportation / Customer Installation. </li></ul></ul></ul>
  8. 8. 3-5 Year Vision <ul><li>To provide Six-Sigma Quality, 100% on-time delivery and More “Value” for less for Champion Doors Door Assemblies, Manufactured within a Quick Response, Toyota Production System Culture Supported by Competent Salary Professionals and a highly motivated Self Directed Hourly Workforce. </li></ul>
  9. 9. The Planning Process The Toyota Production System – House Value Stream Planning & Mapping Microsoft Project Planning Tools
  10. 10. The Toyota Production System House The Foundation
  11. 11. Tools - Value Steam Mapping & Planning
  12. 12. The New Facility, Culture & Processes Flat Organizational Structure – two Layers between Hourly & CEO Coaching/Mentoring Management Style Performance Driven vs Seniority Driven Expecting Nothing less than Quantum Leap Improvements in Quality, Delivery, Cost Performance & Associate Morale. Weekly Individual & Monthly Department Rewards to Promote the Behavior we want to see. Americanized Toyota Production System. Clear Requirements – Visual & Written
  13. 13. Clear Process Requirements (Most Cells) Visual & Written Work Instructions (Sample of one Cell)
  14. 14. Visual - Safety Supplies & Cell Supplies Gloves & Glasses (A variety of Glove Types)
  15. 15. Packaging Supplies Metal Clips Banding Strapping
  16. 16. Proper Labeling Practices
  17. 17. Written - Final Packaging Process <ul><li>Final Box Single, Double & Transom Orders after Approval Sticker is Placed on the Unit (con’t): </li></ul><ul><ul><li>Final Box Singles (con't): </li></ul></ul><ul><ul><ul><li>Tape the Order Below the Fragile Label. </li></ul></ul></ul><ul><ul><ul><li>Write the Order Number And City on the top of the Fragile Label. </li></ul></ul></ul><ul><ul><ul><li>Place the Printed Box on Top of the Door with the Champion Name at the Top Portion of the Door. </li></ul></ul></ul><ul><ul><ul><li>Place a Strap across the middle of the Box, apply a Metal Clip and Pull Tightly on the Strapping to eliminate any slack. </li></ul></ul></ul><ul><ul><ul><li>Place the Box with the Label Side Out in the Singles Finish Goods Rack. </li></ul></ul></ul>
  18. 18. The New Facility & Processes One Piece, Inline, Repetitive Pull Process Flow Ergonomically Designed Cells “ Quality at the Source Process” - Pride in Manufacturing Visual Factory Associate Take Ownership of their Cell Tour Ready 24/7
  19. 19. Overview of New Facility
  20. 20. Organized Bulk Storage on 16’ High Racks & Wide Aisle to Safely Handle Large Items Neat & Well Organized
  21. 21. Ergonomic Designed Saw Cell – Visual Aids Circular Flow around Workbench for Raw Materials & Equipment to Minimize Walking with Antifatigue Mats Surrounding Bench
  22. 22. Ergonomic Designed Router Cell Neat and Organized Slabs Stored in the Cell for easy Retrieval.
  23. 23. “ State of the Art” Load & Unload Conveyor Driven Coating System Fifteen Single Carriers Designed to each Handle All Shapes & Sizes for the Order.
  24. 24. “ State of the Art” Coating Kitchen & IR Oven Plumbers Nightmare!! But Neat & Clean after two Years with and only 4 hours of unplanned Equipment Downtime. 80 Halogen Lamps Baking At 165 degrees F with Metal Racks Cool To the Touch.
  25. 25. Stain Storage Carts – Ergonomic Designed 360 degree Rotating Stain Cart Neat & Organized Stain Material Hand Staining using a Ergonomically Designed Stain Carrier
  26. 26. Loaded Stain Carts Before Stain & After
  27. 27. Stain Spray Booth & IR Oven
  28. 28. Organized Glass & Lite Frame Cell Well Organized Lite Frames By Style Role Model Cross Training Associates Role Model Cross Training Associates in Glass Assembly
  29. 29. Final Ass’y Doubles
  30. 30. Raw Material Storage & Clear Labeling
  31. 31. Neat & Clean Outside Docks
  32. 32. Adding Hourly Associate Value & Pride to the Process Ownership of Their Cell: Pride in High Quality Work, & Team Work Morning Huddle to Discuss Events, Issues & Today’s Plan. Promotion from within the Hourly Ranks to Salary Positions. Neat & Clean Breakroom & Outside Patio Room – Associate Pride Monthly Department Success - Celebration Lunches
  33. 33. Final Assembly Singles – Pride Label Every Order Gets a Personalized Pride Label signed by the Assembler
  34. 34. Morning Team Huddle Area
  35. 35. Promotions to Customer Service & Engineering from the Hourly Ranks
  36. 36. Clean & Neat Associates Breakroom
  37. 37. Clean & Neat Outside Patio Room
  38. 38. Celebration Lunch – Most Orders Shipped in a Month - April 2008
  39. 39. Thank You for Visiting our Door Division!!!! From: the Door Hourly Associates A special Thank You to all the Hourly & Salary Associates for their hard Work & Dedication for Making Champion Door a Division to be Proud of by Providing one of the Highest Level of Manufacturing & Customer Support Processes in the Industry.

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