The Director’s Chair :“The JLC entertains executives from NGNN with two days of Tours”

August 2009 Volume 3 Issue 8

The Director’s Chair 1

Stop Throwing Money Away, Give Your

“Waste” a Second Chance

1

Lean and Green Make a Terrific Pair

2

FRCSE Designated a New Commanding

Officer

2

Quality Sign will Host This Month’s

“Learning Tour”

3

Brady Corp. Special-izes in Workplace

Concepts

3

Lean Accounting/Cash Collection

Workshop will be Of-fered in September

3

Inside this Issue

Over the course of the past two years, I have been contacted by many cities in the U. S. to help them start a Lean Consortium. To date, I have been contacted by fourteen cities. One of those cities is Newport News, Virginia.

Glenn Marshall, Benchmarking & Sustainability Champion at NGNN, Northrop Grumman Newport News, led the effort to form a Lean Consortium in Vir-ginia. He formed the Virginia Business Excellence Consor-tium, VBEC, in partnership with the Virginia MEP, Manufactur-ing Extension Partnership. This Consortium is modeled after the Jacksonville Lean Consortium.

Glenn is also a long time mem-ber of AME, Association for Manufacturing Excellence. He is currently leading the bench-marking sub group of AME. Glen wanted to accelerate the Lean activities at NGNN and asked me if he could bring a team of executives to Jackson-ville, to get more information on

our Consortium and how it works, and then to take a tour of three or four of our member facilities.

The NGNN team included, Glenn Marshall, Benchmarking and Sustainability Champion, Chris Street, Construction Super-intendent, David Scarlett, Refu-eling Planning Superintendent, Gray Milteer, Construction Su-perintendent, and Bob Granata, Director Service and Support, Value Streams Process Excel-lence. These are the people that build and refuel nuclear powered aircraft carriers. They are cur-rently building the USS Gerald Ford.

I was able to arrange tours of Medtronic, FRCSE, Goodrich Aerospace and Rex Corp.

Jerry Bussell conducted the tour of Medtronic. The NGNN team was thoroughly impressed with the tour of Medtronic, but was really blown away by Jerry’s high energy, enthusiasm, and passion for Lean.

Jeff Colquitt conducted the tour of FRCSE. Again, the NGNN team was duly impressed with all that is going on at FRSCE on the F-18 repair line. The team met Major, the Operations Manager, another strong advocate of Lean who demonstrated high energy, enthusiasm and passion for Lean.

Mark Grabynski gave the tour of Goodrich Aerospace. This time the NGNN team got a chance to see Lean applied in a low volume, high mix manufacturing opera-tion. This is a similar operation to the NGNN operation of building aircraft carriers, and the team was able to learn a lot about how to

An estimated 1.5 million tons of paper is not recycled in Mas-sachusetts per year. The esti-mated value, had the paper been recycled, would amount to more than $100 million dollars.

Many companies have decided to use recycled goods to manu-facture their products. For ex-ample, The book cover for the

latest Harry Potter book was made from recycled paper.

It is estimated that 76% of Americans recycle! Waste Man-agement Recycle America (WMRA) is hosting a Lean Leader’s Meeting in Orlando on August 27th in hopes of improv-ing their current process and to allow JLC members to take a

behind the scene look at where our “waste” goes when its given a second chance.

WMRA will be proving trans-portation and lunch for this event.

Like the saying goes, “One man’s trash is another man’s treasure”.

(by Nicolle Beury)

Stop Throwing Money Away, Give Your “Waste” a Second Chance

Group visiting from NGNN

Have you Heard the Buzz?

4

Director’s Chair (cont.) 6

Lean & Green Cert. Classes are Offered Through JLC Under

State Consortium Grant

7

Follow US!! 8

The Lean Gazette Page 2

RECYCLE!

A 60-watt light bulb can be run for over a day on the amount of

energy saved by recycling 1 pound of steel. In one year in the United States, the recycling of steel saves enough energy to heat and light

18,000,000 homes!

For more information about recycling please visit: http://earth911.com/. Do your part

and make an impact!

How many em-ployees does it

take to screw I a light bulb?

If a company identifies lighting as a waste and as a countermea-sure they switch 25 incandescent bulbs to Compact Fluorescents

Lights (CFLs), which use 66% less energy, they can save

$1,000 over the lifetime of those bulbs. These bulbs also produce less heat and can result in lower air conditioning bills. Lastly, these bulbs last up to 10 times longer so your employees can

spend less time switching bulbs and more time on value added

work.

Lean and Green are the new Brad and Angelina. When used to-gether these two snazzy con-cepts create an attractive couple.

What makes Lean and Green so desirable? They are both fo-cused on the same goal - elimi-nating waste. As a result, com-bining the two efforts is a natu-ral fit and can help to create a sustainable organization and environment.

As a Lean company you already have the perfect structure to identify opportunities to im-prove your companies’ Green profile and save money.

During a Lean event participants actively search for and eliminate waste. These wastes are broken into eight categories: Defects,

Overproduction, Waiting, Not Using People, Transportation, Inventory, Motion and Excess Process.

Environmental waste is often an elusive waste. It is hidden behind the scenes and is not at the fore-front of all lean events, but it lurks behind everything that we do. When you eliminate defects, scrap and overproduction in a process, for example, you are also eliminating the associated envi-ronmental waste involved in pro-ducing these items (energy, water, materials etc.). So, decreasing or eliminating many of these wastes can automatically produce an environmental benefit.

Educating the team about envi-ronmental wastes or Lean and Green and inviting the team to

identify these wastes during this process can increase your envi-ronmental impact even more. The main categories to look for during an event include physical materials, waste product, energy, water and air. Tracking these metrics can help you calculate your Green impact which can often translate into cost savings. For example – how much money are you saving by reduc-ing your electricity and water consumption or waste hauling fees?

When you add Green to your successful Lean program it will result in tremendous gains for your company’s bottom line and the environment paving the way to a truly sustainable future.

(by Jodi Conway, Fla. DEP)

Lean and Green Make a Terrific Pair

FRCSE Designated a New Commanding Officer

On July 10th, 2009 FRCSE ap-pointed the new Commanding Officer, Captain Paul A. Sohl. He was the Executive Officer at FRCSE prior to relieving Captain Timothy S. Matthews, the depart-ing C.O. at FRSCE. Captain Mat-thews has been recognized for his outstanding work throughout his Navy career and has been nomi-nated for Admiral.

The service these two men have dedicated to our country as well as the other 2.5 million in our military is beyond reproach. Each time you see a soldier in uniform be sure and shake their hands and say “thanks”. Think if that was your son, daughter, mother, fa-ther, sister, brother or someone close to you; you want the same respect for them. Congratulations gentlemen and thank you serving our country! (by Nicolle Beury)

It’s easy for all of us to live our daily lives and take for granted our freedom; to be able to play golf on Saturday afternoon, have a BBQ with friends, watch foot-ball on Sunday, or spend time with our loved ones. There are over 200,000 men and women overseas who are serving for our country. On July 10th, 2009 Mr. Rizzo, Faith Landis, and myself were invited to attend the Change of Command Ceremony at Fleet Readiness Center Southeast (FRCSE).

FRCSE was established in 1940. In the past 69 years, FRCSE’s production shops have turned out nearly every type of Navy aircraft - fighter and attack planes, patrol, antisubmarine, reconnaissance, transport, trainer, special configu-ration, and helicopters. The over-all workload for FRCSE has ex-

panded to include the rework of engines, components, and ground support equipment, along with other support func-tions vital to the Fleet. Con-tinuous improvement is prac-ticed in daily operation proc-esses, reduced costs are earned by implementing Lean prac-tices, eliminating “wastes”, and becoming more efficient in overall procedures dramatically improved FRCSE process and the overall operation of their facility.

Former Commanding Officer Captain Timothy S. Matthews receiving award at Change of Command Ceremony.

Lean” and “Taking Action with Lean Accounting” workshops will be available September 17th

and 18th. If you are faced with cash collection issues or are in-terested in strengthening your accounting team by learning new tactics and practices in the field I encourage you to attend. This is a great opportunity for a team to

What if you could improve cash flow by shortening your current cash collection process? Not just shortening cash collection by hours or days, but by weeks! JLC has invited Janice L. Frampton to feature two workshops that will help greatly during this recession.

“Improve cash collections with

work on their current cash col-lections process with facilitation by a proven leader. To register, contact the Jackson-ville Lean Consortium at Faith@leanjax.org . For ques-tions, you may e-mail or call (904) 281-9026. We look forward to seeing you there!(by Nicolle Beury)

Page 3The Lean Gazette

Follow the Learner

The Role of a Leader in Creat-ing a Lean Culture

By Dr. Sami Bahri, DDS

Dr. Bahri’s new book is now available on www.LEAN.org.

Dr. Bahri is the first dentist in the world to implement

Lean. The Bahri Dental Group is a member of JLC. Congratulations, Dr. Bahri, on your success throughout

your Lean journey!

Have you ever passed up an oppor-tunity because you felt it wouldn’t be worth your time? Of course, we would all plead guilty to this accu-sation!

It is important to remember that every opportunity we have gives us the ability to improve. Our re-sponse determines our growth from each experience.

Makes me think back to my child-hood when my parents were en-couraging me to try new things. As I got older and finally gave in I realized I had been missing out on a lot of good things!

The Learning Tour is not an event you want to miss out on! It is such a unique opportunity to have at your finger tips, and the experience will stay with you forever. Compa-

Lean Accounting/Cash Collection Workshop Will be Offered in September

Quality Sign will Host This Month’s “Learning Tour”

Brady Corporation Specializes in Visual Workplace Concepts

Sustaining a Lean environment is what we all strive to achieve through our Lean Journey. Visual Workplace is a key requirement to create a Lean environment and is a core concept in the lean manufac-turing toolbox. In fact, along with practices such as 5S and Standard Work, Visual Workplace serves as one of the foundational elements for successful lean initiatives.

Brady Corporation is also on board for any of you who would like them to help you create a visual workplace at your company free of cost. They will come to your event and help create visual con-trols for your workplace. For more information contact Faith@leanjax.org (by Nicolle Beury)

Brady Corporation visited JLC on July 16th and JLC members filled our office! Brady is undertaking a nationwide education program to promote understanding and use of Visual Workplace concepts in lean manufacturing. Brady Corporation is a label and identification com-pany and currently holds 40% mar-ket share in the U.S. and is well known world-wide.

“The Learning Tour was a great way to address a

problematic process using a quick one day

event. Having outside members on the teams al-lowed us to tap into their experiences and ideas,

which is something that is not possible with an em-

ployee only kaizen event. For example, by

implementing a simple sug-gestion, the receiving area offloaded a container in 25

minutes that would nor-mally take 2 hours. Also, having to explain the proc-

ess in detail opened our eyes into some of the areas and issues we didn’t notice before. The outside partici-pants also walk away with ideas and more experience in Lean concepts. I think

the Learning Tour builds to the strength of the Lean

Consortium along with the image of Pilot!” stated

Eric Brown, Engineering Manager at Pilot Pen,

“Special thanks to every-one who made this event successful along with the

following managers at Pilot for being available!”

— Juan Estrella — Director of Logistics,

— Glenn Spilling — Customer Service Manger

— Mike Stevenson — General Manager

— Tim Witt — General Manager

— Nick Galasso — Credits Manager

Speaks Out after Hosting

JLC’s First Learning Tour!

Participants brainstorming at Learning Tour

nies generally hire in consultants to face problems and resolve issues. Together, as a Consortium, we unite to continuously improve.

I am not begging any of you to sign-up and be a part of this event. I am simply making sure I empha-size the impact this event can have on everyone who attends.

New ideas are what generate inno-vation and innovation is what gives companies a leading edge over the competition.

Don’t let this experience pass you by. Join fellow JLC members on August 20th for the second Learn-ing Tour (hosted by Quality Sign).

Generate new ideas, open your mind, and taste something differ-ent! (by Nicolle Beury)

Learning Tour @ Pilot Pen - 07.07.09

Working with others from different companies is what I liked best.

I learned the value of drawing out a front office process and analyzing the different pieces.

Creating a flow chart to help in decision making is a great idea that I want to take back to my own company!

I loved the quality of the outside team members. They made significant contributions!

This Learning Tour is a great way to motivate other employees!!!

I loved the teamwork and different viewpoints. It was great to learn about the structure of actually performing a Learning Tour as well.

My favorite part was working with others from different companies.

I enjoyed the ability to critique a front office process through Lean.

I learned that outsiders are healthy for your business! I liked the ability to work with others to increase my lean knowledge.

I loved the motivation in improvement!

Intro to Cont. Improvement @ FCCJ - 07.09.09

Very Informative!

The practical application of the concepts was very helpful!

My favorite thing was working in teams, being able to make suggestions.

Great sense of teamwork. Sets a good example of how it can be used.

Activities showed through own participation how changes affected the end result.

Looking forward to coming to more classes!

The Lean Gazette Page 4

Lean for Office @ JLC - 07.21.09

Great class! I loved the whole process!

I liked the hands-on activities & the multiple

ways of teaching.!

I appreciated the focus on admin

issues.

Great class! Thirst for more!.

As soon as I return to work, I’m going to color code

my projects & workload!

My favorite thing was the personal

communication from the Instructors

I learned about streamlining, Kaizen and FIFO today.

I will be using the concept of 5S and watching

for the 8 wastes in my job now.

Intro to VSM @ TBD - 07.22.09

I’m going to review our material handling as soon as I get back to work!

Excellent class - thank you!

I most liked using a real-life example to create a value stream map, and interacting with other

local professionals!

I can definitely use what I learned about swim lanes and a continual

improvement plan in my job.

I loved Mr Joe’s way of explaining!

Thank you for the excellent opportunity to increase my knowledge of lean techniques!

I liked the real life examples. Everyone was able to suggest their ideas!

Intro to 5S @ JLC - 07.23.09

Great class!

I liked the team projects.!

I really enjoyed the activities!

I plan to use 5S and the WorkZone website in my job.

Very informative - Thank you!.

Stimulating activities!

I liked the interaction with the tasks.

I will be using the 5S audit form in my job going forward, as well as the ways I learned to engage a team!

The Lean Gazette Page 5

July 15, 2009

To: Joseph E. Rizzo

Executive Director

Jacksonville Lean Consortium

Subject: Benchmarking Trip of the Jacksonville Lean Consortium

Dear Joe

Our team really appreciated you coordinating our benchmarking trip with your member companies of the Jacksonville Lean Consortium. The fact that your consortium is a working model of a community partnership with businesses that are actively supporting “Enterprise Excellence through shared learning” and leveraging that knowledge is an industry “best practice”.

Our intent is to not only to share our findings within our company, but with the members of the Virginia Business Excellence Consortium (VBEC). We would like to continue to leverage our learning by expanding our network to include your membership to promote ongoing exchanging ideas with our members.

Just as your goal is to have a Jacksonville become a Lean City. We want the Southeast region of Virginia to become a Lean and Green Region. Looking into the future our goal would be to expand our VBEC Consor-tium System to 5 regional consortiums serving all of Virginia in becoming a Lean and Green State.

Together our affiliation with the Association of Manufacturing Excellence is enhancing our capabilities to expand our Learning Network not only in our region but across all of North America. We are firmly behind AME strategic initiatives to lead a Rebirth of Manufacturing and to create more Lean and Green Jobs in North America.

Looking forward to working with you and member companies in the future on our collective journey to Enter-prise Excellence through shared learning.

Glenn Marshall

Northrop Grumman Shipbuilding

Benchmarking & Sustainability Champion

Founding Member of Virginia Business Excellence Consortium

Director At Large for AME

The Director’s Chair “The JLC entertains executives from NGNN with two days of Tours”

The Association for Manufacturing Excellence (AME), is North America’s premier organization for the

exchange of knowledge in Organizational Excellence through the imple-mentation of techniques such as Lean Tools, Leadership, Lean Product Development. This years’ 2009 AME conference offers new ideas and tools to help businesses improve and become more competitive in today’s difficult economy. Change is coming and it is important to stay ahead of

the competition in order to keep a competitive edge.

Visit www.ameconference.org for more information. Contact Joe Rizzo, Conference Chair 2009 AME Conference, at Joe@leanjax.org.

The Lean Gazette Page 6

ning and the selection of and communication of Corporate and Location goals and objec-tives.

The last tour was of Rex Corp., which represented a high volume, low mix opera-tion. As you know, there is a lot to see and learn at Rex. As soon as the NGNN team walked into Rex, they knew

that they were touring some-thing special. Bryan Berry gave the tour and thoroughly im-pressed the visitors with expla-nations of and examples of Lean, Six Sigma, and Green. This year, Rex Corp. won the Green Award from the US Department of Energy.

After all the tours, I was con-cerned that the NGNN team might have felt overwhelmed by the tasks ahead of them and the time and resources re-quired to catch up to the level of the four companies that they toured. Instead, it opened their eyes to what is possible. They returned to NGNN with the conviction and resolve of knowing what they had to do.

Glenn has offered a reciprocal visit of Consortium members to visit and tour the NGNN facilities in Virginia. If anyone is interested in touring NGNN, please let me know via e-mail or telephone.

(by Joe Rizzo)

(Conti. Pg. 1)

implement Lean in a low vol-ume, high mix operation. North-rop Grumman also makes sub-marines and is Goodrich’s prime customer. Goodrich is a prime example of cells, 5S, visuals, met-rics, self empowered teams and Hoshin Planning, which is a new topic for NGNN. The team was awestruck at the degree of plan-

Northrop Grumman group visits FRCSE

Still Time to Sign-up!

Order in Which Classes are to be Taken

?

Step One Step Two Step Three Step Four Step Five Step Six

or

or

or

or

or

VSM can be taken anytime between Intro to CI and Kaizen Facilitator

Intro to Con-tinuous Im-provement

Lean for Office

Equivalent Pro-gram at place of

Employment

Intro to 5S

Participation in 1 or more

5S events

5S Facilitator Training

Intro to VSM

Intro to VSM for Office

Equivalent Program at

place of Em-ployment

Participa-tion in 1 or more Kai-zen events

Kaizen Facili-tator Training

Lean & Green Certificate Classes are Offered Through JLC Under State Consortium Grant

The month of August means back to school for those of you who have chil-dren at home or currently working on a degree. JLC is proud to offer certificate classes through UNF’s Cen-ter for Quality Lean Six Sigma program. Their pro-gram is designed specifically for service-focused organi-zations and service-based functions within manufac-turing organizations. Classes will include the fol-lowing Certifications; Lean & Green Certification, Process Improvement Spe-cialist, Green Belt Certifica-tion, and Green Belt to Black Belt Certification.

Classes are being offered to Consortium members at 25% off the regular rate. If you are not a member and are interested in attending classes you can still be ap-proved and receive signifi-cantly low rates for training.

Lean & Green combines training in both Lean and Green. The Lean portion will teach participants the principles of Lean, the eight wastes, and the tools avail-able to eliminate or mini-mize waste. The Green por-tion trains participants to not only eliminate waste but to also identify activities that will help the environment. Six-Sigma is management methodology driven by data

and it focuses on projects that will produce measurable busi-ness results. It uses a set of quality management methods, including statistical methods, and creates a special infra-structure of people within the organization who are experts in these methods. The state Consortium grant has made it possible for JLC members’ to take advantage of these train-ing opportunities and equip employees with training that will push companies through these economic times. To find out for information about these courses e-mail Faith@leanjax.org or give us a call at (904) 281-9026. We will have training times and class schedules available on our website at leanjax.org. (by Nicolle Beury)

The Lean Gazette Page 7

Page 8The Lean Gazette

4110 Southpoint Boulevard - Ste. 222

Jacksonville, Florida 32216

Who We Are

The Jacksonville Lean Con-sortium is a group of compa-nies and government agen-cies, working together to become more efficient,

more profitable, and there-fore, more competitive in the global market place,

through shared learning and networking in Continuous

Improvement efforts based on Lean principles.

To collaborate to improve the performance of businesses and or-ganizations on the First Coast and to promote economic growth

through the implementation of Lean Thinking and tools.

To provide educational opportunities for members of the organization to effectively implement Lean practices and to work to-

gether to assist member s in achieving world class results through Lean Implementations.

http://leanjax.org

Office: (904) 281-9026

Fax: (904) 281-9029

Mission

Vision

http://jacksonvilleleanconsortium.blogspot.com

In recent months JLC’s Executive Director, Joe Rizzo, has become actively involved with the latest fad! You can now follow JLC on Twitter and Blogger. Get insight into thoughts and

observations from Mr. Rizzo himself.

http://twitter.com/JRizzo43