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Table of Contents
• Expertise and Executive Summary
• Key Results
• Span of Control and Business Collaboration
• Situation (Context) / Action Plan / Results
• Safety Culture Improvement Strategy
• Leadership Development Program ( Q Challenge)
• Strategic Master Site Plan Development and Execution
Executive Summary
Passionate, engaged and resilient leader with proven ability to execute, inspire and transform organizations into
safe, productive and improved value to business and customer. Outstanding ability to drive visionary strategic
planning and maximizing key partnerships and relationships. Dynamic interpersonal and communications skills
enhanced by strong business acumen with expertise in leading, motivating and inspiring teams to reach and
exceed goals. Perfectly suited for an organization seeking an accomplished leader who has the ability to execute
and drive value at all levels of the organization with a strong focus on people and customers. My dream is to
create a future that "why we do what we do" is clear to all while maintaining a respectful harmony in personal
lives and our work while executing flawlessly for stakeholders
Luigi Cusano
Expertise
• Senior Executive Leadership
• Manufacturing, Supply Chain, and
Quality
• Lean Six Sigma Leadership
• Enterprise revenue and margin
growth
• Strategic Planning and Execution
• Technology and Product Realization
• Business Process Engineering
• Safety and Performance Culture
Transformation
• Talent spotting and development
• Aerospace, Electronics, Specialty
Chemical and Industrial Sectors
• Doubled Oven Capacity and
Reduced VOC Emissions 50%
through Innovative Design
• World Class Capital Replacement
quadrupling Print capacity
• Advanced Lean Tools (OEE,
PQPR, PFEP)
• Removed Fear of Near Miss
Reporting
• Improved OSHA Rate from 1.9 to <1 0
• Reduced VOC emissions
• Lean Practitioner Program driving
$12mil in stakeholder value
• Managers became leaders
• Underperformers – some became
stars and some departed
• Celebrated successes
“Don't judge each day by
the harvest you reap but
by the seeds that you
plant.”
- Robert Louis Stevenson
Quality Policy Aligned to Strategy and Results
Rework improvement from
45% to <2%
Margin improvement with 3-
6% material cost increase
and increased depreciation
Delivery and satisfaction
index improved from 60 to
90% and 60 to 83%
respectively
Key Results
2.39 2.5
1.85 1.91
0.92
1.17
0.95
2009 2010 2011 2012 2013 2014 2015
OSHA Injury Rate vs Goal
119
140
161
201
187
2010 2011 2012 2013 2014
Revenue (in millions) vs Plan
69
57
92 97 92
63
75
90
63
75
84
2007 2008 2009 2010 2011 2012 2013 2014
Delivery(OTS)/Customer Satisfaction Index
OTS CSI
22 22
20 19
23 22
0.2 0.2 1 2 3 4
2009 2010 2011 2012 2013 2014
Margin (%) vs Depreciation (Indexed)
Margin Depreciation
0
20
40
60
80
Line P Line Insert Line Cure 1 Line Cure 2
Baseline 2012 2013 2014
World Class
Overall Equipment Effectiveness (OEE ) Trends
76
79
75
74
75
2010 2011 2012 2013 2014
Productivity Total Plant (%)
Key Results - Continued
50
700
3,500
5,500
6,000
6,600
3,000
2,000
150 300
Q1
2011
Q1
2012
Q2
2012
Q3
2012
Q4
2012
Q1
2013
Q2
2013
Q3
2013
Q4
2013
2014
Delinquencies ($000)
225 220
250
430 415
54 54 54 56 58
2010 2011 2012 2013 2014
Labor – Direct vs Indirect
Direct Indirect
Henkel
Manufacturing
Operations
Quality
Assurance,
Control and
Engineering
Process and
Manufacturing
Engineering
Planning,
Material
Replenishment,
Warehousing
and Logistics
Facilities
Engineering,
Security and
Maintenance
Environmental
Health and
Safety
Finance
Human
Resources
Project
Management
and Capital
Design
Engineering
Information
Technology
Customer
Service
Hexcel
Span of Control and Business Collaboration
Henkel
Marketing,
Product
Management
and Sales
Global
Operations /
Environmental
Health and
Safety
Customer
Service, Supply
Chain, Strategic
Sourcing
Research and
Technology
Product
Development
Legal and
Human
Resources
Corporate
Engineering
and Advanced
Manufacturing
Immediate Span of Control Business Leadership and
Collaboration
Hexcel
Cross Functional Collaboration - Global Customer Interactions and Relationships
Cross Functional Collaboration - Regional and Federal Regulatory Agencies
Supplier Qualification and Negotiation
Safety Culture Improvement Strategy
• Context
• Actions
• Outcomes and Results
• 2012 a year of extreme challenge for leadership, team and individuals.
• Experienced deterioration in occupational safety, process safety, environmental
compliance, process reliability and capacity shortfalls.
• We decided this was the last year of such performance shortfalls. So we asked how can
we innovate to achieve our desired results?
• We wanted to be great and to do so required a strong focus on
 Authentic Inspirational Leadership
 Team Building
 Tactics to drive the trust that catapults us up the Team Success Pyramid.
• Our journey has been a good one and we expect to be great!
Safety Culture – Context (Situation)
"I'm not certain you heard me," O'Neill continued. "If you want to understand how Alcoa is
doing, you need to look at our workplace safety figures.“
Paul O’Neill former CEO Alcoa
•Safety Logo and Tagline
•Safety Football
•Safety Challenge
•Marshmallow Challenge
•Safety Fridays
•Safety Day
•PSM / PHA
•Huddle Meetings
•Q Challenge Workshops
•Engagement
•Communications
•Training
•Vision
•Management
Commitment
•Priorities Set
Safety
Summit
Leadership
& Safety
Teams
Team
Building
Safety
Awareness
Safety Culture – Strategy
Jan ‘12 Oct ‘12 Feb ‘13 Jan ‘14 Jan ‘15
• Management’s roles
and responsibilities
• Near Miss Reporting
• Objectivity (Behaviors)
Measured, Observable,
Reliable and Specific
(MORS)
• PIC/NIC
• Positive Immediate
Consequence (PIC)
• Negative Immediate
Consequence (NIC)
• Effectiveness of
(MORS)
• PIC/NIC Incorporation
into management
approach
• Machine Safety
• Other
• Safety program
effectiveness
• Break out teams
identified top three
focus areas
• Communications
• Engagement
• Training
Safety Culture – Journey / Actions
Lock Out Tag Out (LOTO) Job Hazard Analysis (JHA)
Process Safety Management (PSM) 14 Elements
Leadership
Behaviors
Toolsand
Systems
Advanced Root Cause Analysis
Safety Alerts: LCDs
Risk and Hazard RecognitionFMEA / 8D
Process Hazard Analysis (PHA)
Celebrations
• Safety Performance
• Engagement/Participation
• Safety Fridays
• Contests – safety logo, risk identification
• Celebrations
• Safety Day
• PHA’s
• Setbacks as learning opportunities
• Near Miss Reporting
2.39 2.5
1.85 1.91
0.92
1.17 0.95
2009 2010 2011 2012 2013 2014 2015
OSHA Injury Rate vs Goal
Safety Culture – Outcomes and Results
Leadership Development Program
• Context
• Actions
• Outcomes and Results
• Dysfunctional Leadership Team and collaboration was not a common theme
• Performance Management and Accountability not executed. Everyone had outstanding
performance reviews through their careers without getting any feedback as to how they
were really performing
• Goal setting was not SMART (Specific, Measurable, Achievable, Realistic, Time bound)
• Emerging Talent did not have a path for growth and development
• Problems were not being solved, symptoms were masked
• Corporate programs were not available to the leadership team and subordinates
• We decided this was the last year of such performance shortfalls. So we asked how can we
innovate to achieve our desired results?
• We wanted to be great and to do so required a strong focus on
 Authentic Inspirational Leadership
 Team Building
 Tactics to drive the trust that catapults us up the Team Success Pyramid.
Leadership Development Program – Context
 Aim high when recruiting/hiring for leadership and technical roles
 Hire attitude and teach skills
 Production Supervisors an Entry Level Role for Talented Engineers
 Collaboration and Team Work through effective leadership programs
 Q Challenge, ALP, Fierce Conversations® for Supervisors, Managers and Future Leaders
 Pilot training execution and effectiveness in one key area
 Encourage healthy sparring (mental martial arts)
 Align oculars and actions to achieve results
 Challenge and Provoke learning through setbacks
 Formal mentorship
 Obtain black belt in living our values
 Navigate using common instruments
 S.M.A.R.T. Goals
 STRAP (Strategic Plan)
 Cross functional and functional Roles and Responsibilities
Leadership Development Program – Context
2012 2013 2014
Leadership Development– Journey / Actions
• Defined
problem and
collaborated
with Hexcel
Global Leader
for
Development
• Provided
inputs to Q
Challenge
• Q Challenge
Session 1 of 3
• 10 Participants
• Direct and
indirect reports
• Q Challenge
Session 2 of 3
• 10 Participants
• Direct and
indirect reports
• Q Challenge
Session 3 of 3
• 10 Participants
• Direct and
indirect reports
• 8 of 10
participant s
earn certificate
• Q Challenge
Session 1 of 3
• 10 Participants
• Direct and
indirect reports
• Q Challenge
Session 2 of 3
• 10 Participants
• Direct and
indirect reports
• Q Challenge
Session 3 of 3
• 10 Participants
• Direct and
indirect reports
• 10 of 10
participant s
earn certificate
Q Challenge Group 1 Q Challenge Group 2
• Fierce
Conversations
• Direct Reports
and peers
• Fierce
Conversations
• Direct Reports
and
supervisors
Key Programs Sponsored
• Communications
• Engagement
• Training
Key Program Sponsored
• Direct Labor bidding proves
• Develop a strong team
into a High Performance
Team
• Improve team
communications skills
• Shape the Hexcel culture
for the future
• Capitalize on existing
qualities and inspire peer
groups
“The best teams develop themselves further when they are winning, not after they start to lose!”
– Phil Jackson
Q Challenge Program Objectives
Program Concepts
Change
Management
Performance
Maximization
• Strategy to align culture to Hexcel Values
• Leadership effectiveness
• High performance negotiations
• e-coaching (e.g. emotional intelligence)
• Measurement of ROI, POL and ROC
• Performance Strategy and Management
• Customer Marketing and Retention
• High Performance Teams
Common Language and Tools
“I believe that Q Challenge was a very effective leadership course. I have attended
multiple leadership courses in the past that primarily focused on book learning, personality
types, team building, etc. This course focused on situations, interactions and
methodologies to get the most out of yourself and your team.” “Anybody can be a manager
of task, few truly lead.”
“Q Challenge was a different teaching/coaching approach from the traditional previous
leadership trainings I had attended in my career. It was a high energy, very hands on
and interactive exchange of ideas and feedback which made for a very enjoyable and
memorable training. The best and most effective tool is the SMART objectives/goals
technique.”
“Q Challenge is an unusual program in my experience because it concentrates on the person,
on an individual’s responsibility to their employees, to themselves, and to their employer. He
speaks to who you are and what you think of you. I think it is highly effective”
“My most effective concept was finally understanding what is meant by ocular.”
“Q Challenge has been unlike any other training I have encountered because it is not training, it is
coaching. I believe the program is more about becoming self-aware, and recognizing strengths
and weaknesses around you. Q challenge puts you in a position that challenges you to change
your point of view and become a better coworker, employee and ultimately leader.”
Q Challenge – Qualitative Results
Q Challenge – Quantitative Results
Fantastic results in 2013
• Occupational Safety: TAR 0.92
• Top Line Revenue: $201m
• Improved Customer Satisfaction Index from 63% to 90%
• Delinquency reduction from $6.3m to <$350k
• OTD form 48% to 87% (94% Jan’14)
• Executed complex strategic capital projects
• Developed 10 year site plan aligned to STRAP
The challenge for the business in 2014
• Adjust to an unanticipated temporary market decline
• Take the opportunity to use Blue Ocean Thinking to radically
improve our cost structure and agility
• Succession Planning / Right People / Champions
Strategic Site Plan Development and Execution
• Context
• Actions
• Outcomes and Results
• Aged assets circa 30 - 50 years of age with no integration plan for either a Maintenance
Management or Manufacturing Execution Systems
• Constrained capacity low capability of critical process lines and not aligned with market
• Print
• Stack
• Lean design was not factored into legacy material and process flow.
• Material flows caused severe lost time injuries
• Numerous fires, explosions and power interruptions a significant risk to business continuity
• Regulatory remediation compliance with EPA, ADEQ and Pinal County and occupational
health concerns caused by high LEL / VOC exposure to employees during processing
• Title V air permit assumptions were incorrect and did not support the capacity and throughput
expansion need for 2015 through 2022. Required collaboration with ADEQ, Pinal County and
EPA Region 9.
• Customer collaboration and approved qualifications required per AS9100 rev C
• Closed in excess of $30million in capital improvements from 2011 through 2014
Strategic Master Site Plan Development – Context
• Saw
• Cure (Ovens)
Strategic Master Site Plan Development – Objective
Expansion Objectives
Safety and
Environment
Revenue
Development
• Title V Permit / NEIC
• Innovate Process Safety Hazard Elimination
• Occupational Safety Improvement through Automation
• 737 MAX, Acousticap® Programs, HexShield®, Legacy Cores
• Market Retention (the right ones)
• Market Capture (the right ones)
Cost Down
Value Innovation
• Direct Cost Improvement
• Overhead Improvement
• Operating Income Improvement
Execute STRAP Revenue Development of $300m and Margin Contribution of XXGM%
through 2022 at a CGAR of 14%
• Boeing Partnership for
Success (PFS) Program
• Customer Satisfaction
• Rate Readiness 2015-2025
• Customer Technology
Roadmap Alignment
Internal
• Environmental
Sustainability
• Product Stewardship
External
Results
New
Erwin
Ext.
20K
Exist.
Erwin
20K
New
Dip Cure
~40K
AST
New
Multi-purpose
New
Shipping/
Receiving
70K
• 35% of plan executed
• Critical expansion of print and
oven capacity completed ahead
of schedule and below budget
• Collaboration with Boeing and
subcon spec custodians afforded
rapid qualifications
• Collaboration with EPA and Pinal
County afforded Title V permit in
8 months vs anticipated 18
months
• Saw center relocation completed
with improved flow, velocity and
air quality
• Undisputed global capacity
leadership

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Luigi Cusano Portfolio

  • 1. Table of Contents • Expertise and Executive Summary • Key Results • Span of Control and Business Collaboration • Situation (Context) / Action Plan / Results • Safety Culture Improvement Strategy • Leadership Development Program ( Q Challenge) • Strategic Master Site Plan Development and Execution
  • 2. Executive Summary Passionate, engaged and resilient leader with proven ability to execute, inspire and transform organizations into safe, productive and improved value to business and customer. Outstanding ability to drive visionary strategic planning and maximizing key partnerships and relationships. Dynamic interpersonal and communications skills enhanced by strong business acumen with expertise in leading, motivating and inspiring teams to reach and exceed goals. Perfectly suited for an organization seeking an accomplished leader who has the ability to execute and drive value at all levels of the organization with a strong focus on people and customers. My dream is to create a future that "why we do what we do" is clear to all while maintaining a respectful harmony in personal lives and our work while executing flawlessly for stakeholders Luigi Cusano Expertise • Senior Executive Leadership • Manufacturing, Supply Chain, and Quality • Lean Six Sigma Leadership • Enterprise revenue and margin growth • Strategic Planning and Execution • Technology and Product Realization • Business Process Engineering • Safety and Performance Culture Transformation • Talent spotting and development • Aerospace, Electronics, Specialty Chemical and Industrial Sectors
  • 3. • Doubled Oven Capacity and Reduced VOC Emissions 50% through Innovative Design • World Class Capital Replacement quadrupling Print capacity • Advanced Lean Tools (OEE, PQPR, PFEP) • Removed Fear of Near Miss Reporting • Improved OSHA Rate from 1.9 to <1 0 • Reduced VOC emissions • Lean Practitioner Program driving $12mil in stakeholder value • Managers became leaders • Underperformers – some became stars and some departed • Celebrated successes “Don't judge each day by the harvest you reap but by the seeds that you plant.” - Robert Louis Stevenson Quality Policy Aligned to Strategy and Results Rework improvement from 45% to <2% Margin improvement with 3- 6% material cost increase and increased depreciation Delivery and satisfaction index improved from 60 to 90% and 60 to 83% respectively
  • 4. Key Results 2.39 2.5 1.85 1.91 0.92 1.17 0.95 2009 2010 2011 2012 2013 2014 2015 OSHA Injury Rate vs Goal 119 140 161 201 187 2010 2011 2012 2013 2014 Revenue (in millions) vs Plan 69 57 92 97 92 63 75 90 63 75 84 2007 2008 2009 2010 2011 2012 2013 2014 Delivery(OTS)/Customer Satisfaction Index OTS CSI 22 22 20 19 23 22 0.2 0.2 1 2 3 4 2009 2010 2011 2012 2013 2014 Margin (%) vs Depreciation (Indexed) Margin Depreciation
  • 5. 0 20 40 60 80 Line P Line Insert Line Cure 1 Line Cure 2 Baseline 2012 2013 2014 World Class Overall Equipment Effectiveness (OEE ) Trends 76 79 75 74 75 2010 2011 2012 2013 2014 Productivity Total Plant (%) Key Results - Continued 50 700 3,500 5,500 6,000 6,600 3,000 2,000 150 300 Q1 2011 Q1 2012 Q2 2012 Q3 2012 Q4 2012 Q1 2013 Q2 2013 Q3 2013 Q4 2013 2014 Delinquencies ($000) 225 220 250 430 415 54 54 54 56 58 2010 2011 2012 2013 2014 Labor – Direct vs Indirect Direct Indirect
  • 6. Henkel Manufacturing Operations Quality Assurance, Control and Engineering Process and Manufacturing Engineering Planning, Material Replenishment, Warehousing and Logistics Facilities Engineering, Security and Maintenance Environmental Health and Safety Finance Human Resources Project Management and Capital Design Engineering Information Technology Customer Service Hexcel Span of Control and Business Collaboration Henkel Marketing, Product Management and Sales Global Operations / Environmental Health and Safety Customer Service, Supply Chain, Strategic Sourcing Research and Technology Product Development Legal and Human Resources Corporate Engineering and Advanced Manufacturing Immediate Span of Control Business Leadership and Collaboration Hexcel Cross Functional Collaboration - Global Customer Interactions and Relationships Cross Functional Collaboration - Regional and Federal Regulatory Agencies Supplier Qualification and Negotiation
  • 7. Safety Culture Improvement Strategy • Context • Actions • Outcomes and Results
  • 8. • 2012 a year of extreme challenge for leadership, team and individuals. • Experienced deterioration in occupational safety, process safety, environmental compliance, process reliability and capacity shortfalls. • We decided this was the last year of such performance shortfalls. So we asked how can we innovate to achieve our desired results? • We wanted to be great and to do so required a strong focus on  Authentic Inspirational Leadership  Team Building  Tactics to drive the trust that catapults us up the Team Success Pyramid. • Our journey has been a good one and we expect to be great! Safety Culture – Context (Situation) "I'm not certain you heard me," O'Neill continued. "If you want to understand how Alcoa is doing, you need to look at our workplace safety figures.“ Paul O’Neill former CEO Alcoa
  • 9. •Safety Logo and Tagline •Safety Football •Safety Challenge •Marshmallow Challenge •Safety Fridays •Safety Day •PSM / PHA •Huddle Meetings •Q Challenge Workshops •Engagement •Communications •Training •Vision •Management Commitment •Priorities Set Safety Summit Leadership & Safety Teams Team Building Safety Awareness Safety Culture – Strategy
  • 10. Jan ‘12 Oct ‘12 Feb ‘13 Jan ‘14 Jan ‘15 • Management’s roles and responsibilities • Near Miss Reporting • Objectivity (Behaviors) Measured, Observable, Reliable and Specific (MORS) • PIC/NIC • Positive Immediate Consequence (PIC) • Negative Immediate Consequence (NIC) • Effectiveness of (MORS) • PIC/NIC Incorporation into management approach • Machine Safety • Other • Safety program effectiveness • Break out teams identified top three focus areas • Communications • Engagement • Training Safety Culture – Journey / Actions Lock Out Tag Out (LOTO) Job Hazard Analysis (JHA) Process Safety Management (PSM) 14 Elements Leadership Behaviors Toolsand Systems Advanced Root Cause Analysis Safety Alerts: LCDs Risk and Hazard RecognitionFMEA / 8D Process Hazard Analysis (PHA) Celebrations
  • 11. • Safety Performance • Engagement/Participation • Safety Fridays • Contests – safety logo, risk identification • Celebrations • Safety Day • PHA’s • Setbacks as learning opportunities • Near Miss Reporting 2.39 2.5 1.85 1.91 0.92 1.17 0.95 2009 2010 2011 2012 2013 2014 2015 OSHA Injury Rate vs Goal Safety Culture – Outcomes and Results
  • 12. Leadership Development Program • Context • Actions • Outcomes and Results
  • 13. • Dysfunctional Leadership Team and collaboration was not a common theme • Performance Management and Accountability not executed. Everyone had outstanding performance reviews through their careers without getting any feedback as to how they were really performing • Goal setting was not SMART (Specific, Measurable, Achievable, Realistic, Time bound) • Emerging Talent did not have a path for growth and development • Problems were not being solved, symptoms were masked • Corporate programs were not available to the leadership team and subordinates • We decided this was the last year of such performance shortfalls. So we asked how can we innovate to achieve our desired results? • We wanted to be great and to do so required a strong focus on  Authentic Inspirational Leadership  Team Building  Tactics to drive the trust that catapults us up the Team Success Pyramid. Leadership Development Program – Context
  • 14.  Aim high when recruiting/hiring for leadership and technical roles  Hire attitude and teach skills  Production Supervisors an Entry Level Role for Talented Engineers  Collaboration and Team Work through effective leadership programs  Q Challenge, ALP, Fierce Conversations® for Supervisors, Managers and Future Leaders  Pilot training execution and effectiveness in one key area  Encourage healthy sparring (mental martial arts)  Align oculars and actions to achieve results  Challenge and Provoke learning through setbacks  Formal mentorship  Obtain black belt in living our values  Navigate using common instruments  S.M.A.R.T. Goals  STRAP (Strategic Plan)  Cross functional and functional Roles and Responsibilities Leadership Development Program – Context
  • 15. 2012 2013 2014 Leadership Development– Journey / Actions • Defined problem and collaborated with Hexcel Global Leader for Development • Provided inputs to Q Challenge • Q Challenge Session 1 of 3 • 10 Participants • Direct and indirect reports • Q Challenge Session 2 of 3 • 10 Participants • Direct and indirect reports • Q Challenge Session 3 of 3 • 10 Participants • Direct and indirect reports • 8 of 10 participant s earn certificate • Q Challenge Session 1 of 3 • 10 Participants • Direct and indirect reports • Q Challenge Session 2 of 3 • 10 Participants • Direct and indirect reports • Q Challenge Session 3 of 3 • 10 Participants • Direct and indirect reports • 10 of 10 participant s earn certificate Q Challenge Group 1 Q Challenge Group 2 • Fierce Conversations • Direct Reports and peers • Fierce Conversations • Direct Reports and supervisors Key Programs Sponsored • Communications • Engagement • Training Key Program Sponsored • Direct Labor bidding proves
  • 16. • Develop a strong team into a High Performance Team • Improve team communications skills • Shape the Hexcel culture for the future • Capitalize on existing qualities and inspire peer groups “The best teams develop themselves further when they are winning, not after they start to lose!” – Phil Jackson Q Challenge Program Objectives Program Concepts Change Management Performance Maximization • Strategy to align culture to Hexcel Values • Leadership effectiveness • High performance negotiations • e-coaching (e.g. emotional intelligence) • Measurement of ROI, POL and ROC • Performance Strategy and Management • Customer Marketing and Retention • High Performance Teams Common Language and Tools
  • 17. “I believe that Q Challenge was a very effective leadership course. I have attended multiple leadership courses in the past that primarily focused on book learning, personality types, team building, etc. This course focused on situations, interactions and methodologies to get the most out of yourself and your team.” “Anybody can be a manager of task, few truly lead.” “Q Challenge was a different teaching/coaching approach from the traditional previous leadership trainings I had attended in my career. It was a high energy, very hands on and interactive exchange of ideas and feedback which made for a very enjoyable and memorable training. The best and most effective tool is the SMART objectives/goals technique.” “Q Challenge is an unusual program in my experience because it concentrates on the person, on an individual’s responsibility to their employees, to themselves, and to their employer. He speaks to who you are and what you think of you. I think it is highly effective” “My most effective concept was finally understanding what is meant by ocular.” “Q Challenge has been unlike any other training I have encountered because it is not training, it is coaching. I believe the program is more about becoming self-aware, and recognizing strengths and weaknesses around you. Q challenge puts you in a position that challenges you to change your point of view and become a better coworker, employee and ultimately leader.” Q Challenge – Qualitative Results
  • 18. Q Challenge – Quantitative Results Fantastic results in 2013 • Occupational Safety: TAR 0.92 • Top Line Revenue: $201m • Improved Customer Satisfaction Index from 63% to 90% • Delinquency reduction from $6.3m to <$350k • OTD form 48% to 87% (94% Jan’14) • Executed complex strategic capital projects • Developed 10 year site plan aligned to STRAP The challenge for the business in 2014 • Adjust to an unanticipated temporary market decline • Take the opportunity to use Blue Ocean Thinking to radically improve our cost structure and agility • Succession Planning / Right People / Champions
  • 19. Strategic Site Plan Development and Execution • Context • Actions • Outcomes and Results
  • 20. • Aged assets circa 30 - 50 years of age with no integration plan for either a Maintenance Management or Manufacturing Execution Systems • Constrained capacity low capability of critical process lines and not aligned with market • Print • Stack • Lean design was not factored into legacy material and process flow. • Material flows caused severe lost time injuries • Numerous fires, explosions and power interruptions a significant risk to business continuity • Regulatory remediation compliance with EPA, ADEQ and Pinal County and occupational health concerns caused by high LEL / VOC exposure to employees during processing • Title V air permit assumptions were incorrect and did not support the capacity and throughput expansion need for 2015 through 2022. Required collaboration with ADEQ, Pinal County and EPA Region 9. • Customer collaboration and approved qualifications required per AS9100 rev C • Closed in excess of $30million in capital improvements from 2011 through 2014 Strategic Master Site Plan Development – Context • Saw • Cure (Ovens)
  • 21. Strategic Master Site Plan Development – Objective Expansion Objectives Safety and Environment Revenue Development • Title V Permit / NEIC • Innovate Process Safety Hazard Elimination • Occupational Safety Improvement through Automation • 737 MAX, Acousticap® Programs, HexShield®, Legacy Cores • Market Retention (the right ones) • Market Capture (the right ones) Cost Down Value Innovation • Direct Cost Improvement • Overhead Improvement • Operating Income Improvement Execute STRAP Revenue Development of $300m and Margin Contribution of XXGM% through 2022 at a CGAR of 14% • Boeing Partnership for Success (PFS) Program • Customer Satisfaction • Rate Readiness 2015-2025 • Customer Technology Roadmap Alignment Internal • Environmental Sustainability • Product Stewardship External
  • 22. Results New Erwin Ext. 20K Exist. Erwin 20K New Dip Cure ~40K AST New Multi-purpose New Shipping/ Receiving 70K • 35% of plan executed • Critical expansion of print and oven capacity completed ahead of schedule and below budget • Collaboration with Boeing and subcon spec custodians afforded rapid qualifications • Collaboration with EPA and Pinal County afforded Title V permit in 8 months vs anticipated 18 months • Saw center relocation completed with improved flow, velocity and air quality • Undisputed global capacity leadership