Nick Sykes Lean Coordinator Process Owner: 3.1.1 Kaizen Process 3.1.1 Nick Sykes Lean Coordinator Process Owner: 3.1.1

Company Overview Hixson has been servicing the military, aerospace, and commercial aircraft industry for over 50 years. Our 40,000+ square foot facility located in Newport Beach is home to over 110 employees. The Company Has Four Key Focuses: Quality Delivery Communication Pricing Awarded SEA’s Leadership & Culture Award and Supply Chain Innovation Award SEA Stage 1 Certified Supplier Nadcap Certified

Hixson’s Capabilities Anodize Black Oxide Chem Film Vacuum Cad Cad Plating Shot Peen Nickel Plating Passivate Tin Plating NDT Chrome Plating Phosphate Painting Copper Plating Brush Plating Grind Gold Plating Silver Plating

Kaizen Process 3.1.1 Details Process Owner: Nick Sykes Master Trainer: Jennifer Kent Key Steps in Process: Preparation Details Develop Kaizen Process Plan Strategic Goals Continuous Improvement Objectives Value Stream Maps Annual Planning Details Review collected data Select Kaizen events Select Champion, Process Owner, and Kaizen Leader/Team Schedule Kaizen event Obtain Champion approval and resources Bi-monthly Implement Details Review/Revise: Review collected data Brainstorming Select improvement initiatives Implement improvement initiatives Create standard work Implement training Ongoing Assessment Details Monitor and assess implemented improvement initiatives Adjust and improve process initiatives as needed Ongoing Communicate Details Create report outs Communicate results (ref-1.1.2) Ongoing Talk about inputs

Identify Need for Kaizen Criteria for Kaizen Event Problem is identified, but solution is unknown Small in scale with urgency needed for process improvement Small incremental improvement that can be completed within the time frame of the kaizen event

Kaizen Team Team Leader – Facilitates event and ensure action items are assigned and completed Co-leader – Training to be a future Kaizen Team Leader Event Coordinator – Liaison with all stakeholders and responsible for preparing final report out presentation Process Champion – Management representative responsible for attaining necessary resources for team Process Owner – Process user responsible for sustaining change Subject Matter Experts (SME’s) – Experienced process users Outsider – Usually supplier and/or customer to process

Team Photo

Pre-work Occurs at least one week prior to kaizen event Kaizen refresher training Review/create value stream map Create kaizen scope sheet Estimate budget and submit for pre-approval

Value Stream Map

Preparation for Kaizen Occurs during the week prior to kaizen event Purchase pre-identified equipment and supplies Ensure that maintenance crew will be on call during event Coordinate with Production to ensure that all kaizen team members’ job duties are covered if necessary

Day 1 – Kaizen Rules One person=one vote Ask questions There are no bad ideas Plans must be sustainable to be successful No ideas are criticized! Work hard Keep an open mind to change Have fun! Keep a positive attitude No blame for anything Respect each other

Day 1 – Planning Begin brainstorming in dedicated kaizen room Use spaghetti diagram flowchart, document suggestions, etc. Move to work area to discuss ideas and continue brainstorming Rate ideas according to impact on business and difficulty to implement

Implement Changes Select improvement initiatives Assign tasks to each person No “normal work” is allowed Team leader assigns new tasks and monitors progress Organize action items list for any outstanding items to be completed

Implement Changes

Assessment and Follow-up Debrief team Identify most valuable and least valuable changes Solicit ideas to improve kaizen process Update department dashboard to measure results Meet at least once per week for the following month to review results, change ineffective items, and audit for sustainability

Assessment Debrief team Solicit ideas to improve kaizen process Identify most valuable and least valuable changes Update department dashboard to measure results

Standard Work & Training Update/create standard work instructions Train all process users to follow new process

Report Out Present kaizen event’s success to executive leadership Occurs approximately one month after kaizen event All team members participate in presentation (not just team leader or management) Executive leadership is not allowed to criticize improvements Executive leadership should ask, “what else do you need from me to continue successfully?”

Before and After Before After Post before and after photos in work area Before After

Thank You! Contact info: Nick Sykes Lean Coordinator (949) 645-4800 x4641 Nick@hixsonmetalfinishing.com www.hixsonmetalfinishing.com