Lean Six Sigma Gary Purcival Roseburg Forest Products
Gary Purcival “It’s in the People” • Lean Six Sigma Blackbelt • 19 years Manufacturing Experience • 8 years Continuous Improvement Experience • Lean and Lean Six Sigma Certified • Expertise: – Subject matter expert in Lean and Six Sigma tools – Organizational team building – Teacher / Mentor /Coach Lean Six Sigma – Process & Machine center optimization – Toyota Production System
Who is Roseburg Forest Products? • Privately held company that was started in 1936 by Kenneth Ford. • Current owner, Allyn Ford who is also President and CEO. • Products include: Lumber, Plywood (Hardwood and Softwood), Veneer, EWP, Particleboard, Melamine, Softwood Chips, and Wood pellets.
• Our company employees 3,000 + people. • We are committed to our communities. • We own 650,000 acres of timberland in Oregon and California.
Lean is… A Business Philosophy of Continuous Improvement Based on Setting Standards Aimed at Eliminating Waste Through Participation of All Employees BEHAVIOR CULTURE SYSTEMS EXPECTATIONS TOOLS ACCOUNTABILITY
• "It is not necessary to change. Survival is not mandatory.” W. Edwards Deming Kiichiro Toyoda
Why Lean & Six Sigma ? Our Values • Safety •We RESPECT our people •We are COMMITTED to our communities • Culture •We make DECISIONS for the long term •We practice INTEGRITY in all we say and do •We create a COMPETITIVE EDGE in all we do • Profitability Our Vision • Survival Roseburg Forest Products is a progressive, closely- held forest products company, building value with timberland, safe and efficient manufacturing and highly capable people. We market quality products and superior customer service at a profit to sustain growth.
Test Today ? NO!!! • Kanban • Pareto Analysis • Kaizen • Regression Analysis • Work Instruction Kanban • DMAIC Process • Value Stream Mapping • Box Plots • Value Added • Control Charts • Non – Value Added • Poke Yoke • Standardized Work • 5 Why’s Problem Solving • Measuring System Analysis • A3 Root Cause Analysis • Total Productive Maintenance • Visual Factory
The Secret!! What Puts World Class Companies Ahead of The Rest ?
Flavor of The Month ? Trust & Teamwork TOC = Theory of Constraints QC Circles Lean Continuous Improvement What is The Next flavor?
• Importance of Skill-Based Training … Truly Empowering Work Groups to Think and Act For Themselves …
Traditional vs. Progressive Skill
• 2 people are smarter than one • 3, 4, 5, 6, 7, 8 people are smarter than 2 • For 25 years you have paid for my hands, you could have had my mind for free!
3M, A.B. Dick Company, Abbott Labs, Adolph Coors, Advanced Micro Devices, Aerospace Corp, Airborne, Alcoa, Allen Bradley, Allied Signal, Ampex, Apple Computers, Applied Magnetics, ASQC, Atmel, Baxter Pharmaseal, Beatrice Foods, Bell Helicopter, Boeing, Bombardier, Borden, Bristol Meyers - Squibb, Bryn Mawr Hospital, Campbell Soup, Cellular 1, Chevron, Citicorp, City of Austin, TX, City of Dallas, TX, Clorox, Cooper Ind, Dannon, Defense Mapping Agency, Delnosa ( Delco Electronics in Mexico), Digital Equipment Corp, DTM Corp, Eastmen Kodak, Electronic Systems Center, Empak, Florida Dept. of Corrections, Ford Motor Company, GEC Marconi, General Dynamics, General Electric, Hazeltine Corp, Hewlett Packard, Holly Sugar, Honeywell, Intel, Junior Achievement, Kaiser Aluminum, Kraft General Foods, Larson & Darby, Inc, Laser Magnetic Storage, Lear Astronics, Lenox China, Litton Data Systems, Lockheed Martin, Loral, Los Alamos National labs, Martin Marietta, McDonnell Douglas, Merix, Microsoft, Morton Int'l, Motorola, NASA, Nat'l Institute of Corrections, Nat'l Institute of Standards, Nat'l Semiconductor, Natural Gas Pipeline Company of America, Northrop Corp, PACE, Parkview Hospital, Pentagon, Pharmacia, PRC, Inc, Qualified Specialists, Ramtron Corp, Rockwell Int'l, Rohm & Haas, Seagate, Society of Plastics Egineers, Solar Optical, Sony, Star Quality, Storgae Tek, Symbios Logic, Synthes, Technicomp, Tessco, Texaco, Texas Commerce Bank, Texas Dept. of Transportation, Texas Instruments, Titleist, Trane, TRW, Ultratech Stepper, United States Air Force, United States Army, United technologies, UPS, USAA, Verbatim, Walbro Automotive, Walker parking, Woodward Governor, Xerox
• 1987: In purchasing Toyota had 337 employees, GM had 6,000. • 1990: Cost of materials, tools parts, Toyota 27%, GM 70%. • 1990: Making 8 million cars a year, Toyota had 74,000 employees, GM had 850,000. • 1990: At the end of the line, at the final inspection, GM had 28 employees, Toyota had 1.
Financial Results Page
• The power of working as a team • Feel the power of continuous improvement
• In 1986 Toyota had 1.5 million employee suggestions • In Toyota Kentucky on average each year, there are 90,000 employee suggestions • In all, 95% of the suggestions are implemented!
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