04 13-12 operations management powerpoint

Dudley – The Future is now!

February, 2012

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Agenda

Introduction

Technology – Ever changing world

Dudley’s Strategy

Innovation in Finishing

Key Points

- Timing

- Facility

- New Skills & Training

Volumes - 2012

Finishing Organizational Changes

Process Details – Q & A

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History of Gentex and Essilor of America

Largest manufacture in the Dudley, MA area

Produce corrective lenses and coating for ophthalmic industry worldwide

Gentex optic was acquired by Essilor in 1995

Employees 400 people, 12 hour shift intervals, 7 days a week

Forbes magazine list “The World’s Most Innovative companies”

Iconic products such as, Varilux and Crizal.

Three R&D centers US, France and Singapore

Joint- Ventures

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The World Around Us

The world gets smaller each and every day

The internet now gives everyone the ability to know everything

The rate of change is mind blowing

Finding that unique niche that separates you from everyone else is not so easy

Continuously improving everything everyday is not a luxury

Innovation is a “must have”

Change is inevitable. Those that win aren’t afraid of it and know how to manage it

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Technology

What are some of the new technology in last 25 years that have revolutionized our society, industry, culture, mankind…..

–Internet–Cell Phone–GPS–RFID

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The need

Dudley Competition

Unit Cost Gap

Unit Cost

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Dudley Strategy

Two Strategies

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OPERATIONAL EXCELLENCE

InnovationContinuously Improve

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Innovation in the Finishing Dept.

►Plan/Communication started Jan 2012

►Auto-sort = A gateway technology

►Integration of the Technologies

►Automation Phase 2

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Current State - Dudley Inspection Lines Today

½Label Maker

Manual Degate

Manual Sort

ManualSort

Manual Verify

½Runner

InlineAudit

½Label Maker

Manual Degate

Manual Sort

ManualSort

Manual Verify

½Runner

InlineAudit

½Label Maker

Manual Degate

Manual Sort

ManualSort

Manual Verify

½Runner

InlineAudit

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Future State - New Inspection Process

FIP Phase II

Integrated System 3 Automatic Degating

machines 4 ASM (Cosmos) 8 Universal Operator

Stations (Sort/Verify/Audit)

RFID Carrier Transport and SCADA

traffic control. Capacity 60K lenses in 24

hours

Auto Degate

Auto Sort

Auto Degate

Auto Degate

Loader

Auto Sort

Auto Sort

Auto Sort

UniversalUniversal

Universal Universal

Universal Universal

Universal UniversalUnloader

Auto Accum

ASM by-pass

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Planning

Macro – Key Points

–Facility work --- (January – March)

–Components arrive --- (March – April)

–Installation --- (March – May)

–Debug/Pilot/Training --- (May – July)

–Production Mode --- (July – August)

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Planning

Short-term Horizon

–1C line, robot validation --- (Jan – Feb)

–1A line, ASM validation --- (Jan – Mar)

–Facility preparation --- (Jan – Mar)

• Office Moves

• QC Cafeteria closing (1 month)

• PMS Meeting location changed (IIP & Coating)

• Temporary dust prevention walls installed

Phase II Auto

QC MeetingRaw Mat’l

Maint

QC BreakQC Offices

Coating

QC Blue Rm

Polar Molding

Clear M

oldingClear M

olding

QA

Distr

Distr

Auto, Eng Offices

Distr

Second Floor North

First Floor North

First Floor South

Second Floo r South

Second Floor West

Existing Facility Layout 8/1/12

Finishing QC

EH&S

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Training

What?

March - August 2012

Log in training

Safety Overview

Operational Training

FIP II DATA ,Trend, OEE Matrix Reporting Capability Overview

Training

Basic Maintenance

Skilled Maintenance -AUTO TECH

When?

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Total Volumes - 2012

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Clear Volumes - 2012

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Polar Volumes - 2012

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Organizational Changes

New Positions created from FIP–Auto-Tech–Loader/Unloader–Maintenance Lead

Positions not required in FIP

–Picker/Label maker

–Runner

–Degator (Secondary)

–Sorter for 80% of Clear Products

–Mispack checker

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Organizational Changes

Q1 Q2 JUL AUG SEP Q4

DL 28.5 29.5 29.5 20 20 20

Reduction of 38 positions total across the 4 shifts

We have a reduction in force policy: Voluntary lay-off option

Temporary staff

Final Notice

Outplacement Services

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How Can I Prepare Myself for the Future?

LEARN Everything You Can!

– Take part in all of the innovation projects and training.

These are skills you can take with you anywhere.

– Continuous Improvement will be very different in the

future here but look what you have already learned?

• 7 wastes

• 5S

• Structured Problem Solving

• How to work as a Team

• …………and more to come!

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Questions?