DDEES, LLC & Full Circle Quality
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Transcript of DDEES, LLC & Full Circle Quality
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{DDEES, LLC & Full Circle Quality
Don Dees CEO & PresidentCell: +1 (616) [email protected]
Web Site: DDEESLLC.com&Web Site: FULLCIRCLEQUALITY.com
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Don DeesMobile: +1 (616) 902-2894 Email: [email protected] Web Site: DDEESLLC.comWeb Site: FULLCIRCLEQUALITY.com
Full Circle Quality performs the following:
1. Consulting Services Coach to implement & sustain Quality SystemsLEAN Manufacturing Processes Problem Solving General Management/Leadership ProcessesStamping, Welding, Plastic Injection Molding, Painting, AssemblyMaterial Handling & Logistics
2. Inspection/Sorting and Containment Sorting/Containment Incoming Inspection Vehicle InspectionStatistical Sampling Root Cause Analysis General Rework of parts
3. Assistance in Hiring Technical Experts Hire North Americans with Specific Skills to Help in China or in NA
4. TrainingQuality SystemsLEAN Manufacturing Problem SolvingLeadership Technical Training
We have over thirty (30) Professional Team Members with Manufacturing Experience of over 25 years per person.
We have a team of Technical Experts (Process Engineers) with years of experience with Automotive OEM’s, who can help you solve any of your Stamping, Welding, Plastic Injection Molding, and Painting issues. We specialize in Quality and LEAN.
We also perform Third Party Inspection & Repair Services.
We have People who can Train your Team on all of the subjects listed above.
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Don Dees
•Vice President of Quality•Vice President of Manufacturing $1 Billion savings per year from
improvements in warranty Instituted Commonization of
Vehicle Sub-Systems and Components; thus saving DaimlerChrysler an additional $2 Billion per year.
• Top American Leader Developed the TPS
Training Materials & Trained the TM’s
•CEO & President Private Equity Three (3) Portfolio
Companies Ten (10) Manufacturing
Plants $400M in Sales Revenue Annual ongoing cost
savings of over $17M per year $20M of cash generated
from reducing inventory levels
New Product & Markets
Proven Lean Operations & Implementation Experience: (Trained from the “floor up”) Trained by Toyota in Japan (Best Japanese TPS trainers in the
World) not by book, theory, or consultants. Applied Lean Knowledge by starting up New Toyota Plant. (1st Year
it won JD Power) Ground up plant launch: Toyota Hiring Process, Developed the TPS
Training & Trained the first 600 TM’s, Launched the Plants(2), Improved NA Suppliers w/TPS
I have implemented these LEAN/TPS tools in OEM’s (GM, DaimlerChrysler & Hyundai), Supplier Companies (BHM Technologies, China), and NON-Automotive Companies (Deere, Cat & China Suppliers); in Both Union & Non Union Environments and in Countries & Cultures across the World.
Proven Ability to Find Talent, Develop Leaders, Teach & Coach, Develop a Great Team, and Get Results Multiple Success Stories in many different Cultures & Countries Experience with aspects of corporate financing & restructuring Successful in New Business Start-ups Successful in Sales & Marketing USP Products Successful in Innovating New Products & New Markets Experience in B2B, B2C, Wholesale, Retail, Dealerships &
Aftermarket
“PROVEN CHANGE AGENT”
•Director of Paint Engineering•Plant Manager•Experience includes: USA & Canada Germany England Japan
•Vice President of Quality & Service Hyundai Quality improved to the top #1 non-luxury vehicle nameplate Started Service Contract Business Started Certified Used Car Program
DDEES, LLCFULL CIRCLE QUALITY,
LLC•CEO & President Consulting Company of
Professionals that assists Chinese and NA Companies
Quality & LEAN Manufacturing Third Party Inspection &
Containment of Suspect Poor Quality Parts
Training Technical Assistance Contract Employees “Headhunter” Assistance
Donald (Don) DeesMobile: +1 (616) 902.2894 Email: [email protected] Web Site: DDEESLLC.comWeb Site: FULLCIRCLEQUALITY.com
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{
Examples of Improvements made Before & After LEAN Manufacturing
Results! Our clients are obtaining results of between 17 and 35 ROI.In other words, for every dollar spent implementing LEAN, they are saving 17 to 35 times this amount of money the next year.
Example of a Project just completed in China
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Results from LEAN Manufacturing Project (8.5 Month Project)Safety• Have now gone over 200 Days in a row without any Safety Accidents in the
Plant(s)
Quality (Customer)• Went from 1,000 PPM’s to Zero PPM’s & Zero QIR’s for six (6) Months in a row• Went for Last Place (#16 in 4/2011) to First Place (#1 in 4/2012) in Suzuki’s
Ranking of Stamping & Welding Suppliers in China• Went from being on the “NOT allowed to Bid on New Work List” (because of past
performance and lack of quality processes) in Q3 of 2011 to “Preferred Supplier List” in April 2012 with Suzuki, Chang An, JCI, LEAR and other Customers.
Quality (Internal)• Went from Checking & Repairing 300% of the parts to 0% Checking & Repairing of
the parts on eight (8) totally different Final Assembly Part Numbers (IP Cross Car Beam, Seats, Steering Column Support Bracket, Radiator Assembly, Engine Tubes, Others)
Delivery• 100% On Time Delivery for six (6) months in a row• Eliminated the need for a Third Party Warehouse for Finished Goods• Eliminated 33% of the Inventory ($4M USD)
Cost• ROI of 17 Times what was spent to Implement LEAN Manufacturing• Saved Manpower, Space, Scrap, Inventory, Needs for new Capital Equipment,
Others
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5S & Visual Management
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Entrance into the Plant Before LEAN
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Entrance into the Plant After LEAN
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Entrance into the Plant After LEAN
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5s & Visual Mgt. Before LEAN
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5s & Visual Mgt. After LEAN
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Safety
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Before LEANSafety Chain IssueWall needs RepairedWood in the Window
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Before LEANParts on FloorHose on Floor100% Inspection & Repair
Parts on
Floor
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After LEANSafe Work Heights Safe Standardized Work Practices Zero Inspection & Repair Zero Quality PPM’s to Customer
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LEAN Manufacturing Safety Tools (at employee entrance into the plant)
The light is “Green” if there have been no accidents or no near misses during the past two (2) days.
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Quality
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Before LEANPoor Work Position & Parts on the FloorRepair with a Hammer 100% of the Parts into Correct Shape 100% Inspect & Repair
Bigger Hamme
r
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Quality Samples and Gages Before LEAN
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Quality Samples & Gages After LEAN
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Implemented Error Proofing (Air into Weld Nuts to prevent weld balls getting into the threads)
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Delivery
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Before LEAN“Pearl Diving” into Big Boxes NO FiFONo Pull System for Material Scheduling
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After LEANJITSmall PackagingFiFO“Pull System”
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After LEANJITSmall PackagingFiFO“Pull System”
零件 A
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Cost
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Original Situation had 40 steps in the “Total Process” before LEAN
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Original Situation had only 15 steps in the “Total Process” after LEAN
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Implemented Cost Reduction by Designing Stackable Rack(s) with Wheels (to move with a tugger instead of a Fork Truck)
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People
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Communication Board(s) After LEAN