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- 1. “ How to Evolve Corporate Culture For Long Term Success” A Tutorial by Endpoint Solutions Inc. Endpoint Solutions Confidential
- 2. Simply Stated: “Mfg is Tool Control” “ Consistency in a variable environment” Endpoint Solutions Confidential Less Variability = More output = More $$ “ How” the tool is run, effects profit
- 3. The “Total Control” Architecture Data gathering & reporting P.M Cycle & Product Mix comp Predict Tool Events before scrap Cost & Cycle time reduction A truly ‘lean’ operation Endpoint Solutions Confidential $$$ Statistical Process Control Optimize Tool Sub - Component SPC Advanced Process Control
- 4. The “Business Cycle” Endpoint Solutions Confidential Time # Units Fight to get every unit out the door Can’t meet demand Sales drop off Cut costs Miss market share Completely Stop spending Create “Quality” issues Slow Spending Lay off people “ Quality” issues RMA Hire more Jr. people Inventory Builds
- 5. The “Business Lifecycle” Many cycles can look like: Endpoint Solutions Confidential But, have you gotten “better” at what you make? Higher Quality Faster Cycle time Lower costs
- 6. Typical Corporate Spending Habits Spend $X on product & technology development Spend $Y on equipment to make that new technology But …… Endpoint Solutions Confidential What was spent on systems to control Product & Equip?
- 7. Evolution vs. Revolution Endpoint Solutions Confidential Result: long term benefit is much greater than the cost Time Unit Cost $$$! Revolutionary Cost Curve Investment Deploy ¢ ¢ Evolutionary Cost Curve
- 8. Why Revolutionary Wins -> “Products” Less variability leads to … Better control which enables … Higher Process Capability (Cp) with … Less Human intervention and … Less Fire-fighting all Equal … Better ‘Quality’ Endpoint Solutions Confidential $
- 9. Why Revolutionary Wins -> “Tools” Less Unplanned downtime nets … Less Cycle Time with ... Less Inventory which enables … More “Time” for: Maintenance improvements + Optimization of consumables = More UPH at Less Cost Endpoint Solutions Confidential $$$
- 10. The Endpoint Solutions “How” Endpoint Solutions Confidential People have to get engaged to really understand Remember high school French? Time / Effort % Understanding A journey with your team Tell Them Least Effective Show Them Minimum requirement but only for some people Make Them do it Minimum requirement for most people Make Them tell someone else Most Effective
- 11. Resource Loading Endpoint Solutions Confidential PM Eng Endpoint Eng Eng PM Architect PM Analyst # Hours PM Minimal time from Engineering & Operations teams I.T contribution can be substantial, but manageable Mgr Launch Analysis Eng Ops Eng Solution I.T Code Eng Test Eng Deploy I.T Ops I.T I.T Customer
- 12. Why Endpoint Solutions? Endpoint Solutions Confidential Spend less [time & money] and get much more benefit Time Unit Cost Evolution Deploy Do it Yourself Endpoint Solutions Inc. Deploy
- 13. Results Over Business Cycles Endpoint Solutions Confidential Biz Cycle ‘Valleys’ Deployments
- 14. Thank You Endpoint Solutions Confidential
- 15. Appendix A Riddle SPC Case Study Endpoint Solutions Confidential
- 16. A Riddle What do all these have in common? “ Quality is Free” by Philip B. Crosby “ Principles and Practices of TQM” by T. J. Cartin “ Introduction to TPM” by Seiichi Nakajima & Norman Bodek “ Good to Great” by Jim Collins “ Built to Last” by Jim Collins “ 5S for Operators: 5 Pillars of the Visual Workplace” “ Lean Manufacturing That Works: ….” by Bill Carreira “ The Toyota Way” by Jeffrey Liker “ Toyota Kata” by Mike Rother “ Stop Smoking” By millions of New Year’s Eve’ers Endpoint Solutions Confidential Appendix
- 17. Top 10 ‘Six Sigma’ Program Failure Points Mechanistic template-dependent unimaginative problem-solving Losing your executive support base Losing unit integrity Failure to retain currency with state-of-the-art methodologies Going Native – becoming part of the problem Lone Ranger – are you leading if no one is following? Prophet in the Wilderness – being too far ahead of your time Flawed and excessive metrics Relevancy lost – ROI vs. common sense and goodness Ice Cream team – failure to substantively engage Endpoint Solutions Confidential Reference: Elias & Associates LLC
- 18. SPC Everybody “knows about SPC” …. Right? But do you really know “how” to use it effectively? Endpoint Solutions Confidential SPC is only a “Data gathering & reporting” tool Required as “Foundation For Advanced Mfg operations” Do you get beat up by SPC? Appendix Or
- 19. The “Time & Money” Cycle My classic 1966 Mustang along with my buddies It took time and it took money You never have both together Endpoint Solutions Confidential Appendix