MFGCON21 logo

Operational Excellence

Improving plant floor operations to increase productivity and profit.

Workforce Excellence

Leadership and Culture

Operational Excellence

Technology, Innovation and Strategic Growth

Day 1 Track Sessions

10:45–11:45 a.m.
BREAKOUT SESSION 1

Enhance Your Value Stream View Using Data

Stephanie Parker, Quality Manager, Boon Edam

Many companies use Value Stream Mapping to identify Lean improvement projects and define a desired future state. Boon Edam, a small manufacturing company in Lillington providing made-to-order security and revolving doors, took a different approach by asking the question: Can we use Value Stream Mapping to actively manage an entire business?

In the last two years, Boon Edam has implemented an order management and processing system based on its Value Stream Map of the entire production process, and has established a visual management system, based on the Value Stream Map, to track the status of orders throughout the value stream. The production team has also integrated control charts into this visual system to monitor the ongoing performance of the individual process steps and handoffs. Using these charts, the team can quickly identify performance trends and areas to apply improvement projects. Learn how Boon Edam has successfully integrated Value Stream Mapping and control charting in order to enhance its view of its value stream with data.

 

  • Manage production flow using a value stream view
  • Collect and analyze data to evaluate the health of a value stream
  • Apply standard control charts to continuously monitor value stream performance and identify opportunities for improvement activities

Stephanie Parker is the Quality Manager at Boon Edam in Lillington, NC and has over 20 years of experience in designing, implementing, and improving quality management systems across a variety of industries. She is a Senior Member of the American Society for Quality (ASQ), for which she is currently the Chair of the Conference Council and has previously served as Chair of the Customer-Supplier Division. Stephanie earned bachelor’s degrees in Chemistry and Psychology from North Carolina State University, an MS in Quality Assurance from California State University Dominguez Hills, and an MS in Statistics from Texas A&M University. She is ASQ certified as a Six Sigma Black Belt, Quality Engineer, Quality Auditor, and Supplier Quality Professional.

1:45–2:45 p.m.
BREAKOUT SESSION 2

Southland Group’s Blueprint for Success-How Planning for Success Made it a Reality

Christine Elder, SPHR, SHRM SCP, CSP, PMP, Owner Elder Group Inc.


-Leadership Advantage
 and how the investment in leadership training in 2019 helped to prepare Southland for the uncertainty and chaos of the last 18 months and come out a stronger company.

-Risk Management and Safety Excellence we will discuss SHARP status and how this was attained and sustained for 8 years.

– Risk Identification and mitigation strategies which were developed through the NC State EAP

-How SOAR strategy planning helped to identify Southland’s 5-year goals- brief explanation of this strategy planning and how it affected where they are today. 

Christine Elder is a personable, organized and energetic Senior Human Resources and Risk Management Consultant with 30+ years of experience as a VP, Director and Business Owner. Certified HR and Risk professional with a broad base of strategic HR knowledge.  Chris is a proven strategist with extensive leadership experience, strong business acumen and an entrepreneurial spirit.  She has partnered with companies across North Carolina, the US and globally to seek solutions, develop their organizations and create paths to business success through Leadership Advantage and operational excellence programs. 

3:00–4:00 p.m.
BREAKOUT SESSION 3

Toyota Kata Part 1

Bill Iacovelli, Improvement Specialist, NC State Industry Expansion Solutions (IES), Chris Koontz, Improvement Specialist, NC State IES

  • Kata – a problem-solving approach utilizing scientific thinking and structured routines
  • Mindset used by Toyota to drive sustained continuous improvement
  • Overview of Improvement Kata and Coaching Kata

Bill Iacovelli, is an extension specialist with NC State’s Industry Expansion Solutions (IES). Based out of the IES Concord office, he works state-wide to help manufacturers, businesses, health care systems and public health departments make improvements through Lean and Six Sigma thinking and methodology. Bill assists organizations in developing systematic, long-term Lean implementation and leadership programs. He also trains and develops Lean Six Sigma Green Belts. In twelve years, relative to his project work with them, Bill’s clients (by way of third-party survey) have reported to NIST over $74M in economic impact and over 500 jobs retained or created. Before joining IES, Bill worked for Eastman Kodak Company in technical and supervisory roles in manufacturing and research and development. He was also a Lean implementer, trainer and coach in manufacturing, utilizing leadership coaching, Kaizen and other Lean tools. Bill holds a B.S. in industrial engineering and operations research from Virginia Polytechnic Institute and State University (Virginia Tech) and an MBA (concentrating on manufacturing management and quality management) from the Rochester Institute of Technology (RIT). He is a certified Lean Six Sigma Black Belt. Bill serves on the Association for Manufacturing Excellence (AME) southeastern region board, Jay M. Robinson High School’s engineering and automation academy’s advisory board and is a member of NC State’s academy of outstanding faculty engaged in extension and engagement.

Chris Koontz is an IES Lean improvement specialist based out of the Greensboro, NC office. His focus is on assisting small to medium manufacturers with their lean transformation by teaching lean tools, mentoring staff and facilitating on-site improvement events. Chris has over 20 years of experience in continuous improvement and quality assurance in various manufacturing industries. In recent years, Chris held quality management, operations and continuous improvement roles within the aerospace industry. In his most recent assignment, he served as a subject matter expert for Toyota Kata and leveraged this methodology to greatly reduce operational task times, optimize material flow, implement rapid change-overs and eliminate production errors. Chris holds a B.S. from NC State University and an MBA with an operations management concentration from Regis University. Additionally, Chris obtained his Six Sigma Black Belt in 2001 and AS9100 auditor certification in 2013.

Day 2 Track Sessions

9:00-10:00 a.m.
BREAKOUT SESSION 4

Toyota Kata Part 2

Bill Iacovelli, Improvement Specialist, NC State Industry Expansion Solutions (IES), Chris Koontz, Improvement Specialist, NC State IES

  • Utilizing a tabletop simulation to build a typical kata storyboard and PDCA cycles of learning record
  • Reinforces the training and discussion from Session 1 – practical application

Bill Iacovelli, is an extension specialist with NC State’s Industry Expansion Solutions (IES). Based out of the IES Concord office, he works state-wide to help manufacturers, businesses, health care systems and public health departments make improvements through Lean and Six Sigma thinking and methodology. Bill assists organizations in developing systematic, long-term Lean implementation and leadership programs. He also trains and develops Lean Six Sigma Green Belts. In twelve years, relative to his project work with them, Bill’s clients (by way of third-party survey) have reported to NIST over $74M in economic impact and over 500 jobs retained or created. Before joining IES, Bill worked for Eastman Kodak Company in technical and supervisory roles in manufacturing and research and development. He was also a Lean implementer, trainer and coach in manufacturing, utilizing leadership coaching, Kaizen and other Lean tools. Bill holds a B.S. in industrial engineering and operations research from Virginia Polytechnic Institute and State University (Virginia Tech) and an MBA (concentrating on manufacturing management and quality management) from the Rochester Institute of Technology (RIT). He is a certified Lean Six Sigma Black Belt. Bill serves on the Association for Manufacturing Excellence (AME) southeastern region board, Jay M. Robinson High School’s engineering and automation academy’s advisory board and is a member of NC State’s academy of outstanding faculty engaged in extension and engagement.

Chris Koontz is an IES Lean improvement specialist based out of the Greensboro, NC office. His focus is on assisting small to medium manufacturers with their lean transformation by teaching lean tools, mentoring staff and facilitating on-site improvement events. Chris has over 20 years of experience in continuous improvement and quality assurance in various manufacturing industries. In recent years, Chris held quality management, operations and continuous improvement roles within the aerospace industry. In his most recent assignment, he served as a subject matter expert for Toyota Kata and leveraged this methodology to greatly reduce operational task times, optimize material flow, implement rapid change-overs and eliminate production errors. Chris holds a B.S. from NC State University and an MBA with an operations management concentration from Regis University. Additionally, Chris obtained his Six Sigma Black Belt in 2001 and AS9100 auditor certification in 2013.

10:30–11:30 a.m.
BREAKOUT SESSION 5

Implementing an ISO 50001 Energy Management System, A Success Story

Lindsey Nichols, Corporate Environmental Engineer, Daimler Trucks North America and Michael Stowe, Senior Energy Engineer, Advanced Energy

ISO 50001 is an international standard for energy management systems and is data and performance-driven to ensure continual improvement. Actively and strategically managing your energy consumption will improve your process efficiencies, reduce your operational costs, improve your competitiveness, and reduce your carbon footprint. This presentation will focus on Daimler Trucks North America (DTNA) and its successful journey in the implementation and certification in ISO 50001 across eight of its large manufacturing sites. We will cover the goals, the process, the lessons learned, the team approach, the tools used, including 50001 Ready and the energy mapping spreadsheet, and results. 50001 Ready is a self-guided program for facilities to establish an energy management system and self-attest to its successful completion. Recognition from the US Department of Energy is available to those that complete the program, and it is an excellent preparation for ISO 50001 certification. If you are considering implementing ISO 50001 this presentation will provide you an excellent overview of how it can be done.

  • Recognize the benefits of implementing ISO 50001 for energy management
  • Gain a perspective of the implementation of ISO 50001 across a large and complex multi-site manufacturing organization
  • Understand the benefits of using the 50001 Ready tool 25 task structure to help prepare for ISO 50001 certification
  • Understand the successes and challenges associated with an ISO 50001 implementation

Lindsey Nichols joined Daimler Trucks North America in 2016. She started her DTNA career as Site Environmental Engineer at the Cleveland Truck Plant in Cleveland, NC. There she led the plant’s environmental compliance and sustainability programs through DTNA’s ISO 14001 certified Environmental Management System. More recently, she shifted into the Corporate Environmental Engineering role where her main project to date has been achieving ISO 50001 certification for DTNA’s eight large manufacturing sites. Lindsey is a graduate of Clemson University with a degree in Biosystems Engineering. Upon graduation from Clemson, she worked in the pulp and paper industry.

Michael Stowe is a Senior Energy Engineer with Advanced Energy. He has over 30 years of experience in manufacturing plants including roles as production manager, maintenance manager, and plant engineer. Currently, he works with utilities, equipment vendors, and manufacturing plant teams to find the best technical and most energy-efficient solutions for industrial processes.