June 6 (DAY 2)
A Breath of Fresh Air
How QRM helped RenewAire outpace and outperform much larger competitors
A constant focus on QRM over the past nine years has helped the company to grow rapidly and continually gain market share. Today RenewAire is one of the largest manufacturers of ERV technology in North America, offering the broadest line of ERV models available in the market.
Mr. Gates’ session starts with the competitive edge RenewAire has achieved with QRM. Then he zooms in on the shop floor reorganization from traditional manufacturing to QRM streamlined processes. This reorganization meant retooling the workforce with new, responsive systems. The succes of the story is shown by increased customer satisfaction, reduced cost and gained market share whilst achieving a higher job satisfaction for all.
PHOENIX PRODUCTS COMPANY, INC
QRM Journey – Why. How. What to Expect.
Mr. Scott E. Fredrick is the CEO and co-owner of Phoenix Products Company, Inc (www.phoenixproducts.com) in Milwaukee, WI. Phoenix is a manufacturer of specialized lighting equipment, and also owns a separate division in the welding industry.
In this session mr. Frederick takes you on a jouney of exploration of the company’s condition and how this led to consider a creative solution like QRM. He will show operational and financial statistics to demonstrate and reinforce the need to change as well as the benefits that ultimately came from QRM. He will highlight how many of the QRM concepts are counter-intuitive and subject to controversy. Furthermore he describe how the cultural and human resource issues can be overcome.
ERP Support for Pull Production
As part of his PhD research, mr. Powell examines the support functionality of ERP systems for pull production in SMEs. By using existing theory and insights from four case studies carried out in the Northern part of the Netherlands, mr. Powell constructed a capability maturity model for ERP support for pull production, together with dr. Jan Riezebos (RUG) and Jan Ola Strandhagen (NTNU). At the QRM Conference, mr. Powell will present the theoretical background for his research, as well as make use of practical examples to demonstrate the applicability of the capability model.
How are you playing your cards? From standard to digital POLCA
BOSCH Scharnieren en Metaal is manufacturer of custom engineered hinges and metal constructions for shop interiors. The profile of the company is high mix, low volume. BOSCH competes on speed. Short delivery times and high reliability are essential to its customers. Per year more than 3000 custom orders are being produced.
In this session, mr. Kaanen will take you through their journey from getting enthousiastic about the key elements of QRM to development of PROPOS. In 2007 BOSCH was the first company in The Netherlands to use POLCA as its shop floor control system. Since then the Polca system has been refined and digitalized, resulting in PROPOS software.
Mining Big Results; A Decade of QRM at P&H
P&H Mining Equipment is one of the world’s leading companies in the manufacturing of large scale mining equipment. For the past 10 years, P&H has had a very close working relationship with the QRM Center at the University of Wisconsin. P&H has implemented over a dozen QRM manufacturing cells, a Quick Response Office Cell and a large scale POLCA system. During this time, P&H has reaped the benefits of reduced lead times (QRM numbers average over 500), reduced WIP and higher output. In this session, P&H will cover some of the most significant aspects of the QRM program and experiences at P&H, and share their experiences and how to implement QRM successfully in large scale, low volume manufacturing.
HAN UNIVERSITY OF APPLIED SCIENCES
Opportunities for QRM knowledge sharing across Europe
Dipl.-Wirt.-Ing. Benjamin Bütfering (Scientific Researcher) of the The University of Applied Science Osnabrück and PhD candidate Daryl Powell who works at the Department of production and quality engineering at the NTNU, Trondheim, Norway and Aldert van der Stoel MSc., Researcher and project leader at QRM center Europe at HAN University of Applied Sciences.
Together the three above work on European knowledge transfer and academic collaboration on QRM. The topic of this session lies in how this collaboration is organized and what the objectives are in order to create a European structure to share the QRM knowledge by using knowledge centers and other facilities which are capable of facilitating QRM training in idustry, education and business associations as well as sharing of best practices. Furthermore they focus on quantifiable results of QRM efforts.
KATHOLIEKE UNIVERSITEIT LEUVEN
The Sustainable upside of QRM
Three presentations on QRM and company strategy:
The first session is about the Financial Sustainability of QRM: the Relationship between Operational Flows and Financial Flows by Nico J. Vandaele, prof. dr. Of the Catholic University Leuven (Belgium). In order to understand the relationship lot sizing, overtime and outsourcing are used as generic examples of operational decisions with substantial financial impact.
The second session by Catherine J. Decouttere, ir. is about Sustainability through Design: the Relationship between new product design and QRM business models. Through the use of examples from the Flemish Industry the importance of business model innovation for the success of new prod-ucts/services is revealed.
In the third session the focus lies on Advanced Resources Planning to support Sustainability: the Tactics of Mid term Planning to serve the QRM business model. Kris Lieckens, dr. gives an overview of QRM bases planning principles. A real life industrial example sows the feasibility of the approach.
Change is never easy: Change Management as an Essential Part of QRM Implementations
P&H is in the middle of a rapid demand growth. Demand for P&H equipment is up 35% this year alone. Implementing QRM is a cornerstone strategy for meeting this demand. But with this increased demand is an increased pace of change. With the l addition of their12th QRM cell, P&H is using formal change management. Ms. Roman and mr. Meuller will present how this focus on the human side of change is helping P&H realize the benefits of QRM implementation sooner with higher acceptance and faster business results.
CUSTOMER CHAIN CONSULTING LLC
“But We Are Unique” – Using the 4L Process to Overcome Barriers in Implementing QRM
Customer Chain Consulting LLC, founded in 2007, is dedicated to spreading the awareness and knowledge of QRM through presentations, training, and implementation assistance.
This presentation will draw on the presenter’s experiences in leading operations and then as a consultant working with companies to describe the adoption and successful implementation of QRM through the “4L Process”:
- LEARN: Understand the concepts of QRM while recognizing the benefits that can be gained through implementing a strategy of time.
- LOOK: Assess the current state, including the culture and leadership capabilities that may be a barrier to successful change.
- LEAD: Establish the plan for implementation, define the MCT and FTMS, and then train those who are affected.
- LAUNCH: Recognize the risks and get going!
UNIVERSITY OF GRONINGEN
Working Principles of POLCA – a Socio-Technical View
Prof. dr.ir. Jannes Slomp focuses in this session on the shop floor. Simulation studies indicate a limited workload-balancing effect of POLCA in situations with realistic parameter settings. This opens the question what the reasons are of the success of POLCA in real life cases. We studied three industrial cases and illustrate that the opportunity of the POLCA system to cope with socio-technical design principles is an important explanation for the success of the system in practice. Two of the three companies implemented POLCA successfully. The third company noticed that first some barriers have to be dealt with.
LEAN TEAM/ INTERFOCOS
Thomas Luiten, Hans Gerrese, Eric Hengst
How We Achieved A QRM Number of 1500 in an Industrial Company
The three enthusiastic partners of LeanTeam started as pioneer in QRM 6 years ago by organizing QRM workshops together with Rajan Suri. Core competence is implementing QRM in industrial companies, beside training and coaching people in QRM hard- and soft skills. During their experiences they developed their own model how to implement QRM successfully and thoroughly throughout the complete processes of customers. In this session they will present QRM in the complete width and depth of the process chain.
Using QRM Principles and Techniques to Drive Supply Base Flexibility
Harley-Davidson Motor Company produces heavyweight custom, cruiser and touring motorcycles and offers a complete line of Harley-Davidson motorcycle parts, accessories, riding gear and apparel, and general merchandise. The main topics in mr. Ketter’s presentation are:
- Supply Management and Manufacturing (Manufacturing and Materials Flexibility Initiative)
- Objective: To drive flexible operations in the Harley Davidson supply base to enable to new manufacturing strategy being employed at the facility in York, PA
- Establishing the Direct Materials Flexibility Framework, driving internal and external education, development of metrics and techniques, creating a base line, embedding in the culture.
- Principles applied included MCT, VSM w MCT, systems dynamics thinking.
- Results to date include an accurate picture of where the supply base stands and the ability to focus their resources and high impact suppliers.
Since 1998 Provan ( Belgium ) has been a supplier of metalwork with specialization in laser and plate treatment, profile laser working, welding and assembly. This session is about the creation of 2 QRM cells at Provan. One cell for the assembly of medical treatment couches with the “bucket brigades” to balance the workload in the cell. One cell for the production of stoves: with a visual system of colored flags to coordinate the activities within the cell. In future these cells will be coordinated by introducing POLCA.
Time is changing at Legrand
Legrand has a complete offer, tailored to the commercial, industrial and residential markets, making it a reference worldwide. Control and monitoring of installations, cable management, power distribution, distribution of “voice-data-image” systems
In this session Legrand shares it’s implementation experience with you. Production-cell for slow-moving fittings which are part of a bigger total system. Meanwhile these components were produced in low cost countries and handled on MTS-basis. After re-sourcing Legrand does this in a QRM cell purely MTO. This project was one of three pilot-projects to learn to work with QRM. Legrand creates a QRM-cells in which operators can assemble in full ownership the complete finished product out of components, inclusive the planning and administration of it. MCT-reduction > 50%, Cost-price-reduction totally > 5%; indirect costs about 19%