04 13-12 operations management powerpoint
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Transcript of 04 13-12 operations management powerpoint
Dudley – The Future is now!
February, 2012
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Agenda
Introduction
Technology – Ever changing world
Dudley’s Strategy
Innovation in Finishing
Key Points
- Timing
- Facility
- New Skills & Training
Volumes - 2012
Finishing Organizational Changes
Process Details – Q & A
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History of Gentex and Essilor of America
Largest manufacture in the Dudley, MA area
Produce corrective lenses and coating for ophthalmic industry worldwide
Gentex optic was acquired by Essilor in 1995
Employees 400 people, 12 hour shift intervals, 7 days a week
Forbes magazine list “The World’s Most Innovative companies”
Iconic products such as, Varilux and Crizal.
Three R&D centers US, France and Singapore
Joint- Ventures
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The World Around Us
The world gets smaller each and every day
The internet now gives everyone the ability to know everything
The rate of change is mind blowing
Finding that unique niche that separates you from everyone else is not so easy
Continuously improving everything everyday is not a luxury
Innovation is a “must have”
Change is inevitable. Those that win aren’t afraid of it and know how to manage it
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Technology
What are some of the new technology in last 25 years that have revolutionized our society, industry, culture, mankind…..
–Internet–Cell Phone–GPS–RFID
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The need
Dudley Competition
Unit Cost Gap
Unit Cost
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Dudley Strategy
Two Strategies
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OPERATIONAL EXCELLENCE
InnovationContinuously Improve
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Innovation in the Finishing Dept.
►Plan/Communication started Jan 2012
►Auto-sort = A gateway technology
►Integration of the Technologies
►Automation Phase 2
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10
Current State - Dudley Inspection Lines Today
½Label Maker
Manual Degate
Manual Sort
ManualSort
Manual Verify
½Runner
InlineAudit
½Label Maker
Manual Degate
Manual Sort
ManualSort
Manual Verify
½Runner
InlineAudit
½Label Maker
Manual Degate
Manual Sort
ManualSort
Manual Verify
½Runner
InlineAudit
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Future State - New Inspection Process
FIP Phase II
Integrated System 3 Automatic Degating
machines 4 ASM (Cosmos) 8 Universal Operator
Stations (Sort/Verify/Audit)
RFID Carrier Transport and SCADA
traffic control. Capacity 60K lenses in 24
hours
Auto Degate
Auto Sort
Auto Degate
Auto Degate
Loader
Auto Sort
Auto Sort
Auto Sort
UniversalUniversal
Universal Universal
Universal Universal
Universal UniversalUnloader
Auto Accum
ASM by-pass
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Planning
Macro – Key Points
–Facility work --- (January – March)
–Components arrive --- (March – April)
–Installation --- (March – May)
–Debug/Pilot/Training --- (May – July)
–Production Mode --- (July – August)
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Planning
Short-term Horizon
–1C line, robot validation --- (Jan – Feb)
–1A line, ASM validation --- (Jan – Mar)
–Facility preparation --- (Jan – Mar)
• Office Moves
• QC Cafeteria closing (1 month)
• PMS Meeting location changed (IIP & Coating)
• Temporary dust prevention walls installed
Phase II Auto
QC MeetingRaw Mat’l
Maint
QC BreakQC Offices
Coating
QC Blue Rm
Polar Molding
Clear M
oldingClear M
olding
QA
Distr
Distr
Auto, Eng Offices
Distr
Second Floor North
First Floor North
First Floor South
Second Floo r South
Second Floor West
Existing Facility Layout 8/1/12
Finishing QC
EH&S
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Training
What?
March - August 2012
Log in training
Safety Overview
Operational Training
FIP II DATA ,Trend, OEE Matrix Reporting Capability Overview
Training
Basic Maintenance
Skilled Maintenance -AUTO TECH
When?
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Total Volumes - 2012
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Clear Volumes - 2012
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Polar Volumes - 2012
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Organizational Changes
New Positions created from FIP–Auto-Tech–Loader/Unloader–Maintenance Lead
Positions not required in FIP
–Picker/Label maker
–Runner
–Degator (Secondary)
–Sorter for 80% of Clear Products
–Mispack checker
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Organizational Changes
Q1 Q2 JUL AUG SEP Q4
DL 28.5 29.5 29.5 20 20 20
Reduction of 38 positions total across the 4 shifts
We have a reduction in force policy: Voluntary lay-off option
Temporary staff
Final Notice
Outplacement Services
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How Can I Prepare Myself for the Future?
LEARN Everything You Can!
– Take part in all of the innovation projects and training.
These are skills you can take with you anywhere.
– Continuous Improvement will be very different in the
future here but look what you have already learned?
• 7 wastes
• 5S
• Structured Problem Solving
• How to work as a Team
• …………and more to come!
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Questions?