Multi-company Project Management applied to Manufacturing Improvement Improving Business Performance Team Implementers, LLC Copyright © 2009

MPM2 Improvement Process Vision Improvement Enhancement Project that is highly flexible & integrates the following : Multi-company Project Management Equipment Supplier Expertise Continuous Improvement Experiences DMAIC improvement methodology OEE metrics Team Implementers, LLC___________ Multi-company Management Solutions

MPM2 Improvement Categories Availability Reduce Breakdowns Reduce Changeover Time (Stack, Coil, Die) Minimize Adjustments Quality Defect Reduction Minimize Rework Reduce Start up Impact Performance Speed Optimization (Product mix) Reduce Idle Time Eliminate Minor Stoppages Equipment Upgrades Functionality Reliability Team Implementers, LLC___________ Multi-company Management Solutions

MPM2 Process - Core Ingredients Leadership Team Measurement Team Improvement Teams Cross-Functional Targeted Goal & Timeframe Matched to Customer resources Integrated with Customer equipment access Team Implementers, LLC___________ Multi-company Management Solutions

MPM2 Process Outline Opportunity Assessment -Conducted jointly Environmental Assessment – Performed by Assessor Contract with Customer to Implement MPM2 Leadership Team Formation – MPM2 Awareness, Plan Measurement Team Measurement Team -Formation and measurement of current state Leadership Team Improvement Planning - Set Goals, Organize Improvement Teams Multiple Improvement Teams (simultaneous, overlapping, or sequential) 1st on site event – Analyze & make improvements Homework – Complete assignments from 1st event 2nd on site event – Verify, adjust, standardize improvements Final Homework – Complete training, incorporate on other shifts, etc. Leadership receives report outs from each improvement team event Validation – Measurement Team validates results over specified time Leadership Close Out - Summarize results and lessons learned Team Implementers, LLC___________ Multi-company Management Solutions

Generic MPM2 Process Gantt Chart Team Implementers, LLC___________ Multi-company Management Solutions

Strategic Assessment Purpose/Structure Protect Participants from investing in a process that does not achieve results. Three Part Strategic Assessment process Part 1 Scope – Define operations to be improved Part 2 Opportunity - Determine gap between engineered & actual performance; Verify demand for increased capability. Part 3 Environment - Determine organization fit to implement the MPM2 Completely confidential Team Implementers, LLC___________ Multi-company Management Solutions

Part 2 - Opportunity Assessment Ideal capacity assumes following: Zero breakdowns Zero defects & rework Optimum operating speeds, feeds, set up, etc. Ideal capacity for specified period determined by equipment supplier based on design/use. Current state determined from actual production records for specified period. Opportunity determined by finding the difference between ideal and current state capacity. Demand forecast reviewed to insure utilization of new capacity created by improvements. Team Implementers, LLC___________ Multi-company Management Solutions

Part 3 - Environmental Assessment Evaluates (8) parameters Supportive Leadership - Continuous Improvement Effective Teams - Basic PM Process Standardized Procedures - Flexible Work Rules Work Place Organization - Willingness to Learn Highly subjective over 24-36 hour period Uses P-I-F rating for each parameter. If any parameter fails, MPM2 process is delayed until parameter improves to I of P. Team Implementers, LLC___________ Multi-company Management Solutions

MPM2 Process Benefits Compliments existing systems Incorporates existing improvement ideas No disruption of existing teams or processes Utilizes short term cross-functional teams with a targeted goal and event timeframe Team resources matched to manufacturing Events are integrated with equipment access Team Implementers, LLC___________ Multi-company Management Solutions

MPM2 Process Benefits (cont’d) Consolidates Customer & Supplier experiences Increases focus on improvement efforts Sets clear priorities & high level decisions Applies PM & Lean tools/techniques Focuses engineering expertise on improvement Leadership links all stakeholders Double Digit OEE improvements Team Implementers, LLC___________ Multi-company Management Solutions