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Society of Bulletin - November 2006 Web: http://chapters.sme.org/026/E-mail: sme26toronto@yahoo.ca
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Talk: Making ‘Lean’ stick – Why just applying lean tools is not enough to sustain improvement Speaker: Jeff Holland Lean Operations Expert in the Operations practice of McKinsey & Company, (Elections for the new Chapter Executive will be held before the talk, see page 2.)
La Vedette Banquets - 150 North Rivermede Road Thursday evening, November 30, 2006. 6:00pm Meet and network; 6:30pm Dinner; 7:30pm Talk Please sign-up by November 15. Please sign up with Loris Giuricich by Nov. 15 at 416-448-2225 or e-mail to Lgiurici@celestica.com $35 for members (CMTDMF -Canadian Machine Tool, Die & Mold Federation- included), $45 for non-members, student members $25. Comments: send email to: sme26toronto@yahoo.ca Directions: La Vedette Banquets is located just south of Langstaff Road on the west side of Rivermede Road.
Many attempts at becoming ‘lean’ are not successful because tools and techniques (such as 5S, Kanban, Quick changeover, etc) are implemented without truly addressing the skills, support and leadership needed to bring about sustainable change. To make change stick, a stable change platform is required that simultaneously addresses the operating system, management infrastructure, and mindsets, capabilities, and behaviors of all people within the organization. Becoming a ‘lean’ organization does not happen overnight. It requires time, human investment and a robust strategy for implementation In this discussion, we will: · Examine why Toyota are so successful and look at some of the hidden aspects of how Toyota operate that creates their success. · Address how to think about a strategy for success in implementing ‘lean’
About the presenter, Jeff Holland Jeff is a Lean Operations Expert in the Operations practice of McKinsey & Company, one of the world’s leading management consultancies. He has been located in the Toronto office since January 2001. Jeff’s recent work includes: · For a company in the medical device industry. As part of a global manufacturing strategy: led a plant diagnostic that identified productivity improvement potential of 31% - this would accommodate the predicted increase in demand with minimal investment. Developed lean production system foundations that not only addressed the manufacturing procedures but also the management infrastructure and shifts in mindsets needed to transform their current operations. Also, designed, led and facilitated a series of lean transformation summits to enable corporate Continuous Improvement (CI) team and plant CI directors to implement lean across the network, addressing lean techniques and tools, performance management and coaching
· For a global airline catering company (300+ sites) Successfully led a cross functional client team to develop and implement a company wide Lean transformation ‘Academy’ for site managers/CI leaders including overall approach, specific training modules & training internal company facilitators to deliver workshops. Designed on-site ‘mini’ transformation techniques to supplement ‘academy’ training and embed learning
Prior to working for McKinsey, Jeff worked for Honda UK as New Product Launch Manager at their manufacturing site in the UK and also for Toyota UK as a manufacturing engineer and project manager in body construction, again at their manufacturing site in the UK. He earned his Bachelor of Manufacturing Engineering (1st Class Honors) from Salford University, England. His hobbies include playing classical guitar, hiking & skiing. |
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Upcoming Topics & Schedule 2006-07 (see http://chapters.sme.org/026/ for details) Apr. 30, 2007, - STG – TPS workshop with Toyota representative (preliminary) Mar. 26, 2007, - STG - Lean Plant Tour at CTS of Canada (Tier 1 Toyota Supplier) www.ctscorp.com Feb. 26, 2007, 4:30pm – STG - Lean Plant Tour at Dofasco Inc. www.dofasco.ca Jan. 29, 2007, 5:45pm – STG: The Human Side of Lean – Kanban or Kaizen Workshop Dec. 14, 2006, 6pm – SME - Christmas Event – at “Mandarin” (see note below) Dec. 11, 2006, 5:45pm - STG – The “Six Sigma” Implementation Workshop Nov. 30, 2006, 6pm - SME Dinner Talk & Executive Elections Nov. 27, 2006, 1:00pm–3:30pm - STG - Lean Plant Tour & Workshop at MAGELLAN Aerospace www.magellan.aero (limited to 15 people!)
Please contact Juergen.Boenisch@jbemc.com for STG registrations. Please contact Lgiurici@celestica.com for Regular SME registrations.
Past Events: Nov 1 2006 – 7:00p SME Executive meeting - George Brown College Oct 30, 2006 - 5:45pm SME STG - The Lean Implementation Workshop: Oct 26 2006 - 6:30p SME - Tour Landing Gear Mfg - Messier Dowty Oct 19th , 2006 - SME regional meeting Oct 5 2006 - 6:30p SME Executive meeting - George Brown College Sept 25th 2006 - SME - STG Improve Your Communication Skills effectively in only 60 Minutes Sept 28th 2006 - 6:30p SME – Integran Tour Nano Technology Canada post Canadian blue bird Dragon boat race |
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November SME Board Elections The Election for the new SME Toronto Chapter 26 Board of Directors is scheduled for our Dinner Meeting on November 30, 2006 (see details above). The following is a View of the 2007 candidates. Rick Marmei - Chair 2007 Rick has been a member of the SME for 9 years and several years prior as a student member. He is currently active in our Toronto Chapter 26 and prior to this in Chapter 318 in Vancouver.
Rick has been the CH26 secretary for 4 years and the Chair elect for 1 year. He has been around manufacturing all his life, starting with a family stamping business. He now owns and operates a Tool Design Business that produces designs for Plastic Injection Molds and Stamping dies as well as Product designs. It is in operation for 9 years and was originally established in Vancouver Canada. The business was moved to Toronto in 2001.
Prior to that Rick served an apprenticeship in Mold making and worked for various Toolmakers in Toronto and Vancouver doing design work. He also attended schooling for manufacturing at Durham College (mold making) and George Brown College (Die making). For more information on the company or please look us up at http://axis-design.org .
Dr. Juergen Boenisch, Ph.D., Dipl.-Ing., CMC - Chair Elect 2007 Juergen and his family arrived in Canada almost 3 years ago, with the original intention to stay for only 9 months. But now they just received thire Canadian residency and they are very proud of it! Here in Canada Juergen started EMC, a firm assisting manufacturing companies and service organizations in achieving Business Excellence following the Toyota Production System TPS. He has over 14 years of international executive and consulting experience in Operations Management, Business Transformation, Business Process Development, Supply Chain Management, Strategic & Global Sourcing and Culture Change. Prior to arriving in Canada he was President & CEO for the US rubber division of ThyssenKrupp, one of the world biggest technology groups with more than 184,000 employees. Juergen worked with international companies in Europe and North America such as ThyssenKrupp, Bridgestone Firestone, Caterpillar, AirBoss, W&P Corporation, Rotek, Boehringer, ALCOA Reynolds, CFN Precision, StampTek, Alliance Atlantis and many small and medium sized companies. Juergen holds a Ph.D. in Physics from King’s College, London UK, two engineering degrees from the University of Bremen, Germany and the designation as Certified Management Consultant CMC. He is a Toyota Production System TPS Expert, frequent speaker and well known in the society of Lean Manufacturing, Six Sigma, Supply Chain Management and Business Culture. He is being very active in our SME chapter 26 as well as working with SME Headquarter in Detroit and was invited to speak at 2006 annual SME conference in Los Angeles. Juergen is a hands-on person and started the Special Tech Group STG: The Human Side of Lean at our chapter beginning of this year. He is also member of APICS, AME and CAMC. For questions or feedback please contact: Juergen.Boenisch@jbemc.com or Tel. (416) 839-7759. Ken Shah - Treasurer 2007 Ken, our new Treasurer, is an active member of SME Chapter 26 for the past 2 years. He was a secretary in year 2006. Ken has always enjoyed cooperating with SME Chapter Leaders and working for our valuable members. He graduated with distinction with a degree in Manufacturing Engineering from McMaster University in year 2002 and now working in a Manufacturing Department at Solinst Canada Ltd. in Georgetown, ON." For questions or feedback please contact: shh_ken@yahoo.ca or Tel. (416) 508-4434. The Candidate for Secretary is currently unfilled. _________________________________________________________________________________
Location: Mandarin Buffet Restaurant Date: Dec. 14 2006 6:00 PM Please sign up with Loris Giuricich by Dec. 12 at 416-448-2225 or e-mail to Lgiurici@celestica.com
Dinner cost: $32 (Tax and Tip included) Drinks are extra, + $10-$15 gift exchange
Restaurant phone (416) 451-2222 Click here for Web Page , Click here for Google Map
Everyone is cordially invited to attend our SME Chapter 26 Christmas party. Please come and celebrate with us. This is a social event and will have no talk or tour scheduled with it. There will be a gift exchange. Everyone can bring a wrapped gift with a price range of $10-$15. We wish to make this a regular event. Please come out and join us for the Festive Christmas Cheer. |
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Review of 9 Months STG: The Human Side of Lean By Juergen Boenisch, EMC It’s already 9 months, since we launched our Special Tech Group STG: The Human Side of Lean on Feb. 20, 2006. Now, after 9 events with close to 200 participants, 3 plant tours and On-Site Lean Workshops, we can review this launch as very successful. For those of you who did not have the chance to get familiar or involved with our STG activities, this article is for you.
February 20, 2006: Launch of STG with workshop at CFN Precision Inc., a proud |
employee highlights visual management triggering the Lean Pull system The idea behind STG’s? The idea to initiate STG’s was born through my involvement in the Tech Group “The Human Side of Lean” at SME Headquarter, Detroit. This and a specific event structure of the Canadian Association of Management Consultants CAMC triggered our STG launch. The STG offers additional value to SME members and potential new members by providing a special platform allowing for intensive and active information exchange. A STG shall be initiated and organized by any SME member who wants to highlight or learn more about individual topics of general interest. The idea is to have monthly meetings in the GTA with member presentations, plant tours, guest speakers and discussions corresponding to the theme of the particular STG. |
Why the STG: The Human Side of Lean? The Toyota Production System TPS is one of the most advanced business models on this planet. Toyota’s success is based on · Process Leadership and · People Engagement Their process leadership is achieved mainly through Lean Manufacturing with some Six Sigma Aspects. Lean and Six Sigma are the most widely accepted and successful business process improvement strategies in the world.
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Toyota: Will be the world largest producer of automobiles by the end of 2006, overtaking GM at this minute… But Toyota’s real secret lies in The Human Side and their ability to engage and respect their people for truly sustainable results and continuous improvement. This extremely well defined People Engagement philosophy is backdated to the origin of TPS in the 1940th. In North America less than 5% of companies achieve sustainable results in any improvement initiative and they increasingly realize that the secret lies in actively addressing the “Human Side” rather than the tools. The SME-26 STG: The Human Side of Lean provides an active platform to inform and support companies in implementing improvements with a special focus on The Human Side of Lean. See what we did so far! February 20, 2006 The STG Kick-Off took place at CFN Precision Inc., one of Canada’s leading Lean Manufacturing Plants.
STG Kick-Off at CFN Precision, Barry Wood explaining company values Barry Wood the former president |
pointed out the importance of clear company values, vision and objectives prior to even starting any improvement initiative. “The Human Side Makes or Brakes any improvement initiative.”
The group was exposed to state-of-the-art lean manufacturing principles followed by a workshop highlighting the most important factors for a successful lean implementation.
March 22, 2006 At the second STG event Juergen Boenisch presented his insights about “Supply Chain Integration – Remarkable Expense Reduction through Collaboration”, in preparation to his workshop at the annual SME conference in Los Angeles.
Juergen Boenisch presenting results of Inbound Supply Chain Management The workshop highlighted the systematic implementation of employee-supplier teams resulting in astonishing but also sustainable improvement results.
June 15, 2006 The STG had the opportunity to visit the Letter Processing Plant of Canada Post, one of the most impressive plants in respect to a successful Lean Transformation.
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Scott MacKinnon at the Central Letter Processing Plant highlights corner stones of there very impressive Lean Journey Canada Post - a governmental and highly unionized institution - started there Lean Journey more than 10 years ago. The impressive results were obvious to everybody attending our tour.
June 26, 2006 Angelo Baratta, a long-time Lean and Improvement Practitioner facilitated our STG workshop in June. The title: “Lean Mindware - Creating Business Value with your existing Talents”.
The Hands-On exercise involving all participants was one of the highlights of Angelo’s workshop. |
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The group exercise demonstrated how difficult it really is to imitate Toyota’s Lean solutions. One reason is that most are trying to imitate the output rather than the process that produces that output. Angelo provided a framework for better understanding the Lean Roadmap and explains a sensible approach for starting your Lean Journey to Business Excellence. July 24, 2006 Our next STG workshop was facilitate by Jim Love with a case study on: “Cross Functional Teams to Accelerate and Sustain the Benefits of Lean-Six Sigma Implementations”. Jim is specialized in rapid application of Lean and Six Sigma and was the first practitioner to apply these techniques to white-collar administrative work.
Based on a Case Study Jim demonstrates how to effectively engage a team The largest benefits of Lean and Six Sigma are obtained when addressing cross functional processes. Jim demonstrated how to create and manage dynamic cross functional teams that will develop solutions and truly deliver the promise of Lean and Six Sigma. The case study showed examples of how to take a group from “arms crossed skeptics” on a Monday morning to “engaged and performing” by Friday. August 29, 2006
Canadian Blue Bird is one of the world’s leading bus manufacturers. |
The Canadian Blue Bird plant tour in Brantford including the On-Site workshop was the first STG event where we had to limit the number of participants. Over 30 people signed up for this event shortly after the announcement. This shows the great interest in the subject as well as the acceptance of our SME-26 initiative.
Over 30 people signed up for this event within 5 days after the announcement. Canadian Blue Bird Corporation is well known for the “Yellow School Busses” and is one of the leading bus manufacturers, in the world delivering thousands of school buses produced in a 229000 sq.ft. facility.
Canadian Blue Bird’s Lean Journey began in 2002 and we had the opportunity to experience many aspects of their successful Transformation. They started to create flow, then embrace 5S, Kanban, Standard Work, and Structured problem solving. In 2005, they were selected as one of Industry Week magazine’s top 25 manufacturing companies.
September 29, 2006 We had a Full-House again with Andres Hug facilitating a very interesting and at the same time engaging workshop. Everybody had lots of fun when “Playing with Lego” and competing against each other. |
Full-House again at this STG event focusing on effective communication But we also learned a lot when Andreas addressed The Human Side of Lean with “How to Improve Your Communication Skills effectively in only 60 Minutes - What to say and How to say it”. This 3-color methodology Sturctogram® provides a simple tool to adjust your personal communication style for more effective communication.
In the group exercise different Lego structures were built, here: The House of Business Excellence in progress
October 30, 2006 We had the pleasure to welcome a very special guest from SME Headquarter, Detroit to our last STG event: Terry Begnoche, the Community Relations Manger. Terry is very much interested in working with the local SME chapters and supporting them were ever he and SME can. He drove the whole way from Detroit and back especially for joining us at this event. Terry is also the main driver of the Detroit Tech Group: The Human Side of Lean and a long –time friend of mine.
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Thank you Terry Begnoche for visiting us and driving all the way from Detroit
Almost every event feedback form shows a high interest for more information about Lean & Six Sigma Tools. Following the Toyota Way and Listening to our Customers we decided to add this Lean Tool specific workshop into our STG schedule. Glen Tolhurst a Hands-On and Front Line Lean Implementer introduced “How to implement Lean Manufacturing? – Why it’s NOT Something you want a Process Engineer to do in an Afternoon!”.
Glen Tolhurst explaining the importance of The Human Side for a successful and sustainable Lean implementation
It again became very obvious that employee engagement with good communication is the key element for successfully implementing Lean. The systematic application of the right tools, starting e.g. with Value Stream Mapping as imitative supports The Human Side of Lean and enables fast results plus sustainability.
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Thank you everybody for being part of our STG: The Human Side of Lean and for your support! And
that’s not all we do à Our STG events are not only related to learning, growing and building Business Excellence, but also to having lots of fun! This follows again the Toyota Way where Social Aspects are very important, too!
Over the last months a core SME-26 team and also non SME members have found together for fun activities, the most exiting one was a Dragon Boat Race. We not only managed to set up our own boat: The Dragon Engineers, but also we made it to the 4th place in the competition!
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The Dragon Boat Race was part of the annual Charity Dragon Boat Festival and organized by The Rotary Club of Oakville Trafalgar. Everybody paid for the boat themselves in full and with a little help from SME-26 we managed to show up in the same outfit. What a success and teambuilding event it was!
We hope that this article helped to show what can be done with a little bit of imitative and that we encouraged others to follow and start up another Special Tech Group in their field of interest or expertise. We are here to help and support everybody in making your launch a success. Let’s share our “Lessons Learned” in launching the STG: The Human Side of Lean. Thank you, Juergen Boenisch, EMC For more information about our Special Tech Group STG: The Human Side of Lean and for upcoming events visit our website at http://chapters.sme.org/026/ or contact me at (416) 839-7759 or Juergen.Boenisch@jbemc.com.
Disclaimer: Since the STG: The Human Side of Lean is somewhat guided by The Toyota Production System & The Toyota Way and I (Juergen Boenisch) am frequently referring to Toyota, I am legality obligated to state that I am not affiliated with or employed by Toyota in any means. All information used is publicly available and does not necessarily reflect Toyota’s opinion or way of operation. Neither SME nor I take responsibility for the correctness of the information.
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Invitation of Past SME Executives &
Senor Members to We would like to invite Past SME Executives & Senior Members to join us for a “Round Table Discussion” about SME-26 in general. Since most of you will come to the Dinner Talk & Executive Elections on November 30, 2006 anyhow, we like to meet just before that at 5:00pm. Why a Round Table Discussion? Over the last months, we had several discussions and saw many emails addressing very important SME-26 issues. The raised points begin with our bulletin and how to maintain a constant information flow between our members and the executives and might end with concerns about our current web presents. But we might want to look at one overall question that is related to the SME-26 strategy or more specifically: “How do we all would like to see our SME Toronto Chapter 26 in the future?” Interesting enough, we believe that this question and most of the other aspects have already been discussed and solved by our SME-26 predecessors, past executives and senior members. So lets first “Listen & Learn” from the expertise in our own ranks in order to not invent the wheel again. Therefore, we like to start with this Round Table Discussion to gain a better understanding and feeling about the really important things to build a strong Chapter 26. Please contact Juergen Boenisch at Juergen.Boenisch@jbemc.com or (416) 839-7759 to let him now who is planning to join us on November 30, 2006 at 4:30pm (see Dinner Talk information above for directions) |
What are Biofuels? By Rick Marmei, Axis Tool Design There is a lot of talk about Biofuels these days, but very few people understand what those are. This article is written to clear up a bit of confusion. Bio means Biological. These are fuels that are grown in farmer’s fields and harvested. They can come in the form of Corn oils, Sunflower oils, Canola oil, extracted from soybeans, recycled cooking oil from restaurants, and certain types of wheat. The wasted part of the plant can be made into compost material or turned into feed for farm animals. Some wasted animal oils can also be used. Diesel oil and gasoline are distillates of Crude oil and have thinner consistencies of the Crude oil. Biodiesel is corn oil. Biodiesel is fine, but what about the rest of us gasoline users? Well there is something called Ethanol, which is type of Grain Alcohol and is a substitute for Gasoline. These are not straight amounts of Biomaterial. They are mixed with regular Petroleum fuels in different percentages to make Biofuels. E stands for Ethanol and B stands for Biodiesel. For example E10 is blended 10% ethanol to 90% regular gasoline and B20 is blended 20% Biodiesel to 80% regular diesel.
Common blends are E10, E20, E85, B2, B5, B10, and B20. There are people that also run SVO, which is Straight Vegetable Oil. But the higher the percentage of Vegetable oils the more pre heaters and engine modification that are needed to run the fuel. B20 and E10 will run in an unmodified diesel car.
B20 fuel provides roughly the same amount of energy as regular diesel, but emits about 15% fewer greenhouse gases per liter. If the percentage of Bio fuel increases then the emissions get better and so does the engine performance and reliability, although some engines may need modifications to run them. Testing of Biodiesel in the United States and |
Canada has indicated it produces significantly lower amounts of hazardous air pollutants. The best reductions are seen with B100. The original diesel engine was designed to run on Peanut Oil a Biofuel and was invented by Rudolf Diesel. Diesel was intrigued by the concept of having no spark to ignite the fuel in an engine. The diesel engine uses no spark plugs and relies on high air pressure to raise the temperature in the cylinder to above the flash point of the diesel fuel and igniting it. A very interesting concept. He had his first working model in 1897. Will my vehicle run on ethanol-blended fuel? All gas vehicles are “ethanol-capable” and can use a blend of up to 10% ethanol. This “E10” is a blend of 10% ethanol / 90% unleaded gasoline and is the most common way ethanol is sold to motorists. Since the 1980s, All automakers have covered the use of up to 10% ethanol under warranty, and no engine modifications are necessary to use E10. E10 is a cleaner burning fuel than straight gasoline. For Diesel B20 is also acceptable under warranty. Check your owner’s manual and car dealer before trying it. Bio Buses around Toronto The TTC is trying Biodiesel to see if it will help with emissions, performance and service conditions of their busses. Called “Greening the Bus Fleet”, the TTC has launched a nine-month bio-fuel test on 180 buses. The project, testing a bio-diesel fuel mixture. The TTC has a total fleet of about 1,500 buses. Ontario Hydro has also converted 80 of its fleet to Biodiesel and plan to expand the project to its fleet of 400 trucks. They are currently testing B20 and have said the following “We hope to be able to use blends containing as much as 50% Biodiesel in the future.”
Rick Marmei Axis Tool Design
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George Brown Student Chapter S156 is re-established. By Rick Marmei
The regular meetings of the George Brown Student Chapter S156 has been restarted with help of some dedicated students from the Mechanical and Tool and Die programs. Under the watchful eye of John Camarda the new George Brown Student advisor. George Brown College has allowed the regular chapter executive meetings have been held at the CasaLoma Campus to help with this fact. 4 energetic students attended our last meeting and want to learn how to hold a meeting and for us to help them to sustain a chapter. The SME supports students that are trying to further the education in the Manufacturing areas. We Congratulate the students and wish them well in there efforts with the Student Chapter.
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