training within industry - job instruction...
TRANSCRIPT
2/6/2017
1
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
1
Elements of Woodbridge
Training Within Industry - Job Instruction Woodbridge and the global Journey on TWI JI Presenting to Paul McKay – November 30th, 2014 Michael Gribe and Carlos Vasquez - The Woodbridge Group
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
2
Agenda
• Company and Product overview
• The Woodbridge Production System
• TWI JI Journey @ Woodbridge
• Learnings and status
• Next steps
2/6/2017
2
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
3
Kipling Avenue Plant Woodbridge, Canada
circa 1969
Corporate Headquarters Mississauga, Canada
Company Overview
Private Canadian Company • Established in 1978 • Committed to World-Class Health,
Safety and Environmental Performance • Global Footprint, 60+ Facilities in North & South America,
Europe, Asia Pacific and China
Five Main Product Functions Products designed to deliver comfort, acoustics, energy management, structural and insulating capabilities
Diverse Markets Served Automotive, Commercial and Recreational Vehicle Components, Assembly and Sequencing, Technical Foams, Building Products, Protective Packaging, Diversified Products and Laboratory Services
Supplier of Innovative Chemical Conversion Technologies Chemical research and development, product and process engineering, tooling, manufacturing, technical support, accredited laboratory testing, assembly and sequencing and just-in-time delivery
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
4
Worldwide Presence 61 Facilities In 17 Countries
* Joint Venture ** Technical Agreement
15
9
8
10 14
6
7
5
12
11 16
2
4
17
13
3
1
1. ARGENTINA Pilar
2. AUSTRALIA
Melbourne
3. BRAZIL Betím
Caçapava Camaçari Capivari
Caxias do Sul* São Bernardo
4. CANADA Blenheim, ON* Kitchener, ON
Mississauga, ON Whitby, ON
Woodbridge, ON
5. CHINA Guangzhou*
Shanghai (2 Facilities)
Wuhan* Wuxi*
6. CZECH REPUBLIC
Mlada Boleslav*
7. EGYPT Cairo**
8. ENGLAND
Coventry* Manchester*
9. FRANCE
Boulogne-Billancourt* Trilport*
10. GERMANY Espelkamp* Mörfelden*
Munich* Schwarzheide*
Wolfsburg *
11. INDIA Sanand
12. JAPAN
Anjo* Inado* (Kyushu)
Nanno* Tokyo
13. MEXICO Leon* (2 Facilities)
Mexico City* Puebla*
Saltillo* (4 Facilities)
14. POLAND Bielsko Biala*
15. SPAIN
Barcelona*
16. THAILAND Bangkok*
Gateway* (Plangyao)
17. UNITED STATES Atlanta, GA
Chattanooga, TN* (3 Facilities)
El Paso, TX (2 Facilities)
Fremont, OH Greensboro, NC*
Huntsville, AL Kansas City, MO
Lansing, MI Romulus, MI
Springfield, KY* St. Peters, MO
Troy, MI
2/6/2017
3
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
5
1. Light Passenger and Commercial Vehicle Components
seat cushioning, head restraints, armrests, bolsters, headliners, hood liners,
occupant protection, acoustical foams, bumper absorbers and cargo management systems
2. Recreational, Utility and Military Vehicle Components
complete seats, seat cushions, armrests, head restraints, bolsters, acoustical
applications and cargo management systems
3. Diversified Products bedding products, commercial foams
and furniture foams
4. Protective Packaging One-way packaging, insulated
containers, returnable dunnage, material handling totes
5. Building Products Insulated Concrete Forms (ICF) for residential and commercial new building construction and commercial sound wall systems
6. Technical Foams medical, sporting, packaging, gaskets,
filters, sanding discs, personal care, diaper waist bands and automotive trims
7. Assembly and Supply Services delivering total supply chain management
and state of the art, contract assembly and sequencing
8. Laboratory Services accredited facilities offering polyurethane
physical property testing
8 Business Sectors
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
6
Innovation In All Aspects Of Our Business
• Chemistry
• Product Design
• Manufacturing Processes
• Productivity Improvement
• Employee Creativity
Ontario Green Chemistry and Engineering Award
2/6/2017
4
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
7
NORTH AMERICA
OEM Acura BMW
Chrysler Daimler
Ford General Motors
Honda Mitsubishi Navistar
Renault/Nissan SIA
Subaru Suzuki Toyota
Volkswagen
TIER 1 ACH
Bloomington Seat Dong Kwang/DKtech
Faurecia Grupo Antolin
Guilford HFI
HOWA IAC Insa Irvin
Isringhausen Johnson Controls
JSP Lakeside
Lear Magna
Marwood M-TEK
Magee Reiter NHK Seating
Rieter Automotive Rivas Setex
Span America Swiftco TACLE TISA
Toyota Boshoku Trim Quest
TS TECH TS Trim
UTA Vuteq Yorozu
EUROPE
OEM Audi BMW
Citroen Daimler
Fiat Ford
General Motors Honda
Hyundai Jaguar
Metrocab Renault/Nissan
Opel Peugeot
PSA Renault
SEAT Suzuki Skoda Toyota
Vauxhall Volkswagen
Volvo
TIER 1 Faurecia Gestind
IAC Isringhausen
Johnson Controls KAB Seating
Kigass Landers
Lear Magna Recaro SITECH TACLE
Toyo Seat TS TECH
VW
JAPAN
OEM Ford
Honda Mitsubishi
Suzuki Toyota
TIER 1 Delta
Faurecia Fuji-Seat INADO JCAS
Marubishi Recaro Tachi-S
Toyota Boshoku Toyo Seat TS-Tech
SOUTH AMERICA
OEM Bramont Chevrolet Daimler
Fiat Ford
General Motors Honda
Hyundai Kia
Mazda Mitsubishi Peugeot
PSA Renault/Nissan
Toyota Volkswagen Volvo Truck
TIER 1 AutoLiv
Isringhausen Johnson Controls
Lear MTA
TS TECH Toyota Boshoku
THAILAND
OEM AutoAlliance
General Motors Honda Isuzu
Renault/Nissan Thai Swedish
Toyota
TIER 1 BKS
Cagiva Delta TR
GST JSI
NHK Toyota Boshoku
TSI TS TECH
AUSTRALIA
OEM Ford
GM Holden Mitsubishi
Toyota
TIER 1 Air International
Futuris Automotive Toyota Boshoku
CHINA
OEM Honda
NanJing Nissan
Peugeot
TIER 1 Wuhan Wan Hine
Faurecia/GSK Wuhan Shanghi Flame Lamination
TACHI-S/JCI TSTECH/ GSK Wuhan
INDIA
OEM Honda
TIER 1 TS Tech
Sampling Of Our Customers
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
8
Automotive Applications
2/6/2017
5
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
9
ComforTechTM
Performance Seating Urethanes
Combining chemical expertise with unique technologies and processes, ComforTech™ seat cushioning helps customers achieve the ideal balance between comfort, weight, durability and cost.
Key Advantages
•Advanced product development from prototypes to production
•Custom foam formulation expertise to meet specific performance targets
•Advanced tooling and process capabilities
•Global footprint and state-of-the-art facilities
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
10
SmartSourceTM
Assembly and Supply Technologies
SmartSource™ value added services help customers manage costs and successfully meet today's just in time, assembly and supply challenges.
Key Advantages
•World-class error-proofing technologies
•Proven just-in-time delivery track record
•Reduced cost and continuous improvements
•Dedicated engineering and fully validated assembly process solutions
•Modular assembly expertise in custom process solutions for virtually any commodity
2/6/2017
6
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
11
Woodbridge Production System Why is TWI very
important?
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
12
Initially
YOU
TEAM
2/6/2017
7
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
13
Four Stages of Lean
1) Resistors
2) Fashionably Lean
3) Selectively Lean
4) Lean Practitioners
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
14
Woodbridge Definition of Engagement
1) Teammate who knows what to do
2) Teammate who knows how to do it
3) Teammate who has the resources to do it
4) Teammate who wants to do it
5) Teammate who wants to do it BETTER
2/6/2017
8
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
15
2011
2012
2013
Launch of WPS for the overall organization
Repeat full world audit for conformity for JI
Expand roll out to Asia Pacific for JI
2014
2015
2016
Introduction and Training on TWI JI in Blenheim
Launch of TWI JI Community of Practice in Canada and USA
Pilot JI in 6 alpha sites (Blenheim, El Paso, Kipling, KC, Saltillo, St Peters).
Roll out for JI to North America (Mexico) across all BU
Audits on JI in 6 alpha sites in North America
2017
Expand roll out to Brazil and Argentina for JI
Audit on JI in North America
TWI Journey Overview towards operational excellence
Roll out for JI to North America (CAD, US) across all BU
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
16
TWI JI South America Rollout – Sao Bernardo (Lab / Off Line / Head Rest Assembly) – Headrest example
Average cycle time stabilize; slight increase (1 second)
through better control; reduction in variation and standard
deviation.
2/6/2017
9
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
17
Some early testimonials for the TWI JI roll out
• “Scrap reduced by 50% in first 6 months. Less mistake and increase attention to details (blocking and tackling) not missing labels, on rolls. Attention awareness to details.” El Paso SWF
• “Supervisors freed up 25 to 35% of their time. Standardization across 2 shifts. More ownership with each team member for their part from driver, from Reception upfront, HR.” El Paso Lam
• “Training to same methods. Less time to prepare new employees to be ready. Reduced induction time for new hires from 3 to less than 2 months.” Mexico
• “Save 2 seconds on spray glue gun, reduce overspray and customer takt time, and provide better adhesion toppering process per part. Potential $ savings in labour per year on 1 product code.” Whitby
• “The trainer who used to work on shift 1 and 2 is now working on the 3rd shift. She could not understand why the difference in process between shifts. She is now clear on what she needs to do to train others. One method.” Atlanta
• “I used to work at JCI and never got the training she had. In one week, I was trained on over 12 rotation tasks and was able to master it.” Sao Bernardo
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
18
Learning - Job Breakdown Standard Operator Training
• Force standardization on task across and within each shift.
• Focus on repetitive critical tasks (reduce length).
• Own fully by the hourly SMEs, “breathing and living document”.
• LTR and SOT - waste is eliminated and not documented.
• Several iterations before final.
• Training sheet integrated within plant governance (Job breakdown Vs Work Instruction, Job Safety Analysis).
• Audited regularly by all levels and types of teammates.
2/6/2017
10
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
19
Learning - Subject Matter Expert (SME) and Trainers
• SME is cornerstone of TWI JI system (owning SOT , training matrix, auditing).
• At least 1 or 2 trainers SME per shift per work center.
• Role need to be nurtured: improving skills regularly, may become talent pool for team leader destination role.
• Variation from shift to shift reduced by “forcing collaboration”.
• Follow up (Step 4)/Auditing and Kamishibai
• Unionized Vs non unionized
• Compensation, Recognition and Retention/turnover
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
20
Learning - Management Involvement and Expectations
• Management role critical from start and all the way along the journey (include in orientation of new hires, managers standard work)
• Expectations: “when are we done with TWI JI?”
• Foster cross training across the plant.
• Allow retraining after each Kaizen or change on job breakdown
2/6/2017
11
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
21
Learning - TWI JI and Engagement Level
-0.25
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.25
0.30
-0.50 -0.40 -0.30 -0.20 -0.10 0.00 0.10 0.20 0.30
TWI engaged TWI beginning TWI Not engaged
Linear (TWI engaged) Linear (TWI beginning) Linear (TWI Not engaged)
• Over 36 plants are engaged in their TWI implementation in the Americas.
22 plants in the Americas are auditing at point of operations.
9 plants are in the stage to train their teammates.
5 are still need to select and train their SMEs trainers.
• Correlation between improvements on engagement score and training items is increasing along with TWI roll out from less than .25 to .45 and then .63 when full implemented.
• TWI is one of the accelerator/catalyst like WPS on engagement. More plant teammates are owning elements of the TWI system, the more engaged there are.
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
22
22
TWI DASHBOARD- Example 5
1
25%
Plant's Next Target
33%
WPS Smart Target
Review written SOT's vs.
teammates
understanding the SOT
37
WPS Smart Target
The desired conditon is
to get to the plant's next
target of 100%
Prior itizing and
organization
50%
100%
The plant has completed
91% of SOT's
Number Of Employees (Team Mates)
Number of Employees (Staff)
Number of Work Centers
Number of Production Shifts
WPS Smart Target
Plant's Next Target
20%
WPS Smart Target
100%
Plant's Next Target
Ele
me
nt
5.0
Ele
me
nt
1.0
Ele
me
nt
2.0
Ele
me
nt
3.0
Ele
me
nt
4.0
26%
Plant's Next Target
35%
WPS Smart Target
Plant's Next Target
50% OF Teammates are
at level 2 or lower in
proficiency
Target for Kipling was
25% of teammates as
subject matter experts.
Target has been met.
All teammates to get to
level 3 as plant's next
target
Coaching teammates
more in the process.
Review and revise SOT's
as audits are being
performed based on
feedback.
Only 5% of audits are
successful
All teammates to be
trained to 35% as plant's
next target
The plant has completed
8% of their LTR's
The desired condition is
to get to the plant target
of 20% of completed
LTR's
Prior itizing and
organization
What is the Current Condition? What is the Desired Condition?What is Preventing Us From Getting to
the Desired Condition?
What is the (1) or Next Thing I could Do To
Get Closer to the Desired Condition?
When Can I Check Progress?
(date completed)
8%
92%
% of SOT Ready To Be Audited
Not Ready
Ready
92%8%
% of LTR's at the "IS" State or >
Not Ready
Ready
16.8%
20.2%
26.2%
36.0%
0.7%
% of Team Mates @ Lvl. 3 Proficiency
Training
Planned
Level 1
Level 2
Level 3
Level 4
154
5
Passed Audits @ Point of Operation
Opportunity
Success
75.68%
24.32%
% of SME's in the Employee Population
Employees
not SME's
% of SME's
in thePopulation
TWI Dashboard Reporting
2. Visible and
accessible to all
teammates and
simple enough for
them to read.
3. CI – Paretos – 5Q.
Prove to develop
people and improving
the training. Created
with inputs from all
sites/BUs.
4. Metrics need to be
actionable or lead to
course correction.
Direct reflection of
what is happening on
the plant.
1. Standard reporting
for all plants on TWI
progress. Capture
same data & feature
status, progress or
issues to all level of
management.
2/6/2017
12
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
23
Next steps
• Pursue roll out in rest of Asia Pacific
• Sharing knowledge
• Reduce administration
® are registered trademarks and TM are trademarks which are either owned or used under license by Woodbridge Foam Corporation. © Entire contents copyright Woodbridge Foam Corporation. All rights reserved. January 2015
24
Carlos Vazquez
The Woodbridge Group
Manager WPS Resource Centre
Email: [email protected]
Phone: (915) 471 5259
THANK YOU
Michael Gribe, MBA, CHRP
The Woodbridge Group
Manager Talent & Organization Development
Email: [email protected]
Phone: +1 905-896-3882 ext. 3266