2012 Conference Program
Program - Focus Day22nd October 2012
Building a Leadership Toolbox for Manufacturers
Practical Approaches to Transforming Results
- Understand what it takes to truly transform your results and capability vs. just achieving gradual improvements
- Explore the unique role of leaders and how to empower yourself to lead even if you’re not the person at the top
- Identify and act on opportunities to increase your team’s engagement and commitment
- This is an interactive session with the objective that each participant will walk out of the session with not only some exposure to concepts and tools but specific insights about their circumstances that they can act on immediately
Integrating Change Management Practices into Manufacturing Excellence Programs
- Obtaining employee buy-in when launching new initiatives
- Incorporating change management tools into manufacturing excellence programs
- Understanding the importance of timing around change management training
- Helping staff understand their roles and responsibilities to ensure the success of a new project
INTERACTIVE WORKSHOP: Are You a Learning Organization? Achieving the Next Level of Continuous Improvement
- Assessing the current level of your workforce culture
- Setting a goal and charting a course: What does your organization need to become a proactive manufacturer?
- Moving beyond Continuous Improvement: What defines a learning organization? What can be expected of it? How can this level of engagement and self-improvement be sustained?
INTERACTIVE WORKSHOP: Improving Quality and Compliance Systems for Manufacturers
Workshop led by EtQ USA
- Evaluating the status quo: Are your organization's system performing well? What more can be done?
- Debating the pros and cons of siloed versus non-siloed integration of systems
- Optimizing processes like document control, risk management, and supply chain
- Cultivating a proactive and engaged workforce
INTERACTIVE WORKSHOP: Getting the Most Out of Your Existing Resources
Led by Vista Solutions
- Understanding the capabilities of the assets available to you
- Training your workforce to make the best use of their time and tools provided to them.
- Tracking performance over time to inform manufacturing decision-making and the bottom line
INTERACTIVE WORKSHOP: Achieve Business Excellence Today and Make it Future-Proof for Tomorrow
Led by Cognizant
- Conceptualizing business excellence as a never-ending journey, overcoming numerous business challenges along the way
- How to adopt, achieve and sustain business excellence in operations
- Reducing operation costs through end to end visibility
- How success of extended enterprise can improve manufacturing processes
- Dynamically responding to changing conditions, evolving constrains and emerging opportunities
An Interactive Excercise to Calculate the ROI of Reshoring
- Reviewing the market forces driving both offshoring and reshoring manufacturing decision-making
- Talking about reshoring's impact on R&D, planning horizons, quality control, and response times
- Offering tools to identify and compare the total cost of ownership in national and international operations
Increasing Your Manufacturing Competitive Advantage: It’s About Time!
- Illustrating how lead times impact every facet of a manufacturing operation
- Increasing market share, reducing costs and improving quality by shifting from cost-based to time-based decision-making
- Highlighting the four core concepts of QRM:
- The Power of Time: Why lead time is much more important than most managers realize, and how it influences total operating cost and quality.
- Organizational Structure: How to restructure your organization to minimize lead time throughout the enterprise.
- System Dynamics: How interactions between machines, people and products impact your lead times. As a result, capacity planning, lot sizing and other policies need to be rethought.
- Enterprise-wide Application: QRM is not just a shop floor approach; it is applied throughout the organization, including office operations, engineering, and the supply chain.
- Demonstrating QRM in action: Real-world examples where lead times were reduced by 80-90%. How did that drive productivity?
Rajan Suri
Emeritus Professor
University of Wisconsin-Madison
and Founding Director
Center for Quick Response Manufacturing
Sponsored By See It Solutions
Program - Day One23rd October 2012
Nurturing the American Industrial Commons to Improve US Competitiveness
- Outlining the goals and efforts of Harvard Business School's US Competitiveness Project
- Qualifying what makes American Manufacturing competitive in a global economy
- Developing a strategy to reinvest and reinforce in the root causes of these qualities
- Highlighting ways government, industry, and academia can contribute towards the cause
Bison Gear's Ongoing Work to Innovate, Improve, and Invest in Competitive Advantage
- Developing a skilled workforce both internally and within the community
- Highlighting the role R&D plays in a manufacturing company's well-being
- Illustrating why reshoring and reinvesting in American manufacturing makes good business sense
- Taking great care of your customers: The manufacturer's role in passing success along the value chain
CASE STUDY: Raytheon's "One Million $1 Ideas" Program
A Remarkable Story of Employee Engagement and Continuous Improvement
- Outlining Raytheon's multi-year efforts to go lean one small adjustment at a time through daily workforce consultation and steady cumulative improvement
- Describing the corporate culture --both in the corporate offices and on the plant floors-- that has driven Raytheon's success
- Motivational tools to solicit grassroots contributions: Competition, recognition, entertainment, and a sense of accomplishment
- How far can a continuous improvement culture permeate an organization?
Working with Government and Academia to Train a Manufacturing-Capable Workforce in the United States
Caterpillar's Efforts to Attract a New Generation of Americans to the Skilled Trades
- Reviewing the root causes of the current shortage: How did the available talent pool become so shallow?
- Discussing the current and future labor requirements of US-based manufacturers
- Highlighting projects and programs that are starting to make a difference. How scalable are these beginnings? What more needs to be done?
- Offering experiences and lessons learned so far, and suggestions for how other companies can contribute their efforts to the cause
Direct Digital Manufacturing
A National Program to Bring High Performance Computing Capabilities to American Manufacturing
- How does digital manufacturing increase competitiveness and strengthen American industrial capabilities?
- What challenges have limited the scope of this technology until recently?
- Making advanced data analytics for virtual modeling and simulations affordable and available to SMEs
- Offering access to tools and training throughout the US to make digital manufacturing work
CASE STUDY: Collaborative Problem-Solving in the Quest for Efficiencies
Lockheed Martin’s Multi-Faceted Approach to Operational Excellence
- Working with program partners to align processes, clarify objectives, divide responsibilities, and communicate progress
- Bringing a combination of Lean and Six Sigma tools to bear in consultation with design, supply chain, and operations stakeholders to reduce costs and improve performance
- Showcasing real-world examples of sustained improvement from several major projects
CASE STUDY: Mass Customization Manufacturing
National Oilwell Varco's Experience Equipping the Oil and Gas Industry
- Outlining the challenges involved in building highly specialized and customized machines
- Demonstrating the importance of communication and collaboration between all stakeholders and participants of the manufacturing process
- Calculating time and material requirements for unique and unusual projects
- Offering best practices and lessons learned when engineering and manufacturing variations to a product
CASE STUDY: Overcoming Cultural Challenges and Discovering Region-Specific Advantages in Global Manufacturing
Ingersoll Rand's Experiences in India
- Translating the capabilities and constraints of doing business in India into a source of dramatic innovation
- Capitalizing on India's emerging infrastructure, talent pool, and unique customer base to foster manufacturing productivity
- Creating a progressive and engaged workforce through culturally relevant programming
- Highlighting leadership approaches that drive market share in emerging markets
Keith Sultana
Vice President of Operational Excellence and Global Integrated Supply Chain
Ingersoll Rand
Research Findings from Aberdeen Research and a Practical Roadmap for Success
- What targeted Continuous Improvement is worth if sustained
- The practical realities for mid-sized companies embarking on the Continuous Improvement journey
- The communications barrier & how it can kill success
- How workforce development & a technology framework combined can deliver improvement results at pace
INTERACTIVE WORKSHOP: Improving Shareholder Value – Marrying the Lean Journey to the Strategic Vision
Led by TBM
- Understanding how lean tools apply to value creation and how this drives meaningful business results
- Outlining one journey and best practices which produced rapid and sustainable results with an enterprise-wide process improvement
- Using Lean as part of a comprehensive management system to align strategy with execution
- Customer case study: How to successfully leverage a principle driven and strategic lean approach
INTERACTIVE WORKSHOP: Keeping Current with Today's Productivity Tools
Led by Munro & Associates
- Past success stories are great, but we are being forced into new technologies and a brutal business climate
- Yesterday’s tools allowed us to manage manufacturing complexity; today we need to mitigate manufacturing risk… Early!
- How do we model risk and how do you know what you don’t know?
- Demo of the ability to model unlimited manufacturing options at the development phase
- Live real world application workshop
INTERACTIVE WORKSHOP: Behavior-Based Strategy Execution and Performance Improvement
Led by CLG
- Embedding applied behavioral science in your corporate culture
- Increasing and sustaining top-line grown through thorough business-planning
- Achieving lasting results consistently, with speed, precision, and control through improved leadership impact
INTERACTIVE WORKSHOP: Lean Supply Chains Through Utilization of Advancements in Technology
Led by Lean Supply Solutions
- How advancements in technology can be adopted to drive lean methodologies throughout supply chains
- Innovative applications of technology today
- Examples of innovation in global supply chains today
INTERACTIVE WORKSHOP: The Future of Quality Management in Manufacturing From Design to Operations
- The role of quality in the current business environment
- Review of analysts' predictions for the future of quality in manufacturing operations
- How to improve manufacturing productivity using quality management systems
- Tools to assess your organization's quality maturity, readiness and potential productivity improvement
INTERACTIVE WORKSHOP: Streamlining Manufacturing Processes Using ERP & MES Software Systems
Led by QlikView
- Illustrating the impact a holistic approach to business intelligence software can have on manufacturing operations
- Taking the struggle out of consolidating and analyzing relevant data to inform decision-making
- Making a system work across platforms to allow real-time access and mobile analysis in the office or on the plant floor
- Moving beyond data to include qualitative inputs and a collaborative flow of information between management, designers, operators, and maintenance staff
Strategies to Attract, Develop, and Retain Skilled Workers
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- Discussing innovations in internships, apprenticeships, and collaborations with local educational institutions to deepen the pool of qualified workers --especially among young people
- Identifying the top-performers of the future and making special efforts to grow their skillsets, abilities, and responsibilities over time
- Training the workforce you already have: Novel approaches to cross-training, mentoring, coaching, and career management to keep your staff satisfied and productive
- Creating a self-sustaining and self-perpetuating culture of shared competencies and ongoing cross-training
Program - Day Two24th October 2012
- Describing the metrics being employed across industry to track manufacturing and supply chain performance against overall business and business objectives
- Understanding the impact of organizational structure on devising and implementing performance measures for distributed manufacturing environments
- Overcoming the common hurdles companies face in implementing performance measures
Strategies for Your Organization's Worldwide Operations
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- Debating the extent to which ongoing economic uncertainty and new opportunities in emerging markets are changing the way companies grow
- Comparing the decision-making process of SMEs versus major international companies regarding global operations
- Weighing the impact distance, workforce, and regulation has when deciding to invest or divest operations in a given region
CASE STUDY: Applying Lean Principles to Process and Batch Manufacturing Operations
Kaiser Aluminum's Integration of Lean, Six Sigma, and Total Productive Manufacturing Thinking to Drive Continuous Improvement
- Comparing and contrasting lean concepts for discrete manufacturing versus process manufacturing
- Identifying the unique challenges and opportunities to optimizing operations like batch processing
- Building a CI program through a combination and modification of several strategies to seek efficiencies in formula-based processes
- Reviewing best practices and lessons learned to date. What is the next step for Kaiser Aluminum's CI programming?
CASE STUDY: Reshoring in Action
STERIS Corporation's American-Centric Manufacturing and Supply Chain Strategy
- Discussing the factors informing STERIS decision-making as it insources work from Europe, Canada, and China and expands in the United States
- How STERIS went about evaluating cost savings
- Offering early examples of improved performance, productivity, versatility, and reliability based upon the transition. What is the expectation for this ROI looking forward?
- Outlining the next steps in US production and how this leverage infrastructure, improve quality and reduce costs
- What should other companies take away from STERIS's experience to date?
CASE STUDY: Leveraging a Global Manufacturing Footprint to Respond to Rapidly Changing Demand
Valmont Industries' Plan to Build and Assemble Agricultural Irrigation Equipment Worldwide
- Overcoming the challenges of a limited forecasting model
- Leveraging the best practices of other global manufacturing operations to drive standardization, customer intimacy, continuous improvement and quality control
- Coordinating the output of global sites in response to planting seasons and weather patterns on different continents and hemispheres
- Improving communication between facilities on different continents that operate in different languages
- Building regional flexibility into a international network
INTERACTIVE WORKSHOP: Content to be Announced
INTERACTIVE WORKSHOP: Content to be Announced
INTERACTIVE WORKSHOP: Content to be Announced
CASE STUDY: Launching and Sustaining Lean Initiatives
Jabil Circuit's Two-Year Journey Towards Manufacturing Optimization
- Outlining the planning and decision-making stages behind a push for leaner manufacturing
- Obtaining buy-in from both senior managers and the workforce
- Establishing metrics and performance measurement to monitor and guide change
- Highlighting a few examples of new and revised process implementation to illustrate lessons learned
- Discussing the next steps based on the successes and setbacks experienced to date
Operational Performance Management for Manufacturers
- Defining success and the KPIs involved in reaching a successful outcome
- Measuring, analyzing, and improving business processes and systems based on data
- Making PM an ongoing, real-time exercise
Additive Manufacturing: The Future of Small- and Medium-Enterprise Manufacturing?
Gaining Insights into a Technology Making the Transition from Curiosity to Commercial Operations
- Demonstrating the possibilities additive manufacturing offer to prototyping and small-run production
- Highlighting successful applications of additive manufacturing
- Incorporating additive manufacturing into current processes: Saving time and money on specialty jobs and design-intensive projects
- Scaling the new technology: What are the limitations? How will 3D printers contribute to the future of manufacturing?
- Going beyond skill development, execution and results to put in place a performance system that inspires and supports your workforce to work smarter.
- Engage leadership on methods that multiply results of Lean and Six Sigma programs.
- Create a practitioner culture where accomplishments are highly recognized throughout the organization. Accredit up to a level of Triple Certification.
Case Study led by The Productivity Team
- Setting and achieving sustainable performance goals
- Increasing efficiency and improving manufacturing throughput through variability reduction
- Getting hands-on and collaborative across departments in the pursuit of solutions
MillerCoors' Ongoing Efforts to Reduce Carbon Footprint and Water Usage
- Discussing the corporate culture changes involved in driving eco-friendly projects and programs
- Showcasing improvements and initiatives that cut fuel and water consumption and greenhouse gas emissions
- Where does capital investment and process improvements to address environmental impacts also improve overall performance and productivity?
- Offering lessons learned so far and considering the next steps
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