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August 2009Volume 3Issue 8The Director’s Chair :“The JLC entertains executives from NGNN with two days of Tours”Over the course of the past twoyears, I have been contacted bymany cities in the U. S. to helpthem start a Lean Consortium.To date, I have been contactedby fourteen cities. One of thosecities is Newport News, Virginia.Inside this IssueThe Director’s Chair 1Stop Throwing Money 1Away, Give Your“Waste” a SecondChanceLean and Green Make 2a Terrific PairFRCSE Designated a 2New CommandingOfficerQuality Sign will Host 3This Month’s“Learning Tour”Brady Corp. Special- 3izes in WorkplaceConceptsLean Accounting/ 3Cash CollectionWorkshop will be Offered in SeptemberHave you Heard the 4Buzz?Director’s Chair (cont.) 6Lean & Green Cert.Classes are OfferedThrough JLC UnderState ConsortiumGrant7Follow US!!8Glenn Marshall, Benchmarking& Sustainability Champion atNGNN, Northrop GrummanNewport News, led the effort toform a Lean Consortium in Virginia. He formed the VirginiaBusiness Excellence Consortium, VBEC, in partnership withthe Virginia MEP, Manufacturing Extension Partnership. ThisConsortium is modeled after theJacksonville Lean Consortium.our Consortium and how itI was able to arrange tours ofworks, and then to take a tour of Medtronic, FRCSE, Goodrichthree or four of our memberAerospace and Rex Corp.facilities.Jerry Bussell conducted the tourof Medtronic. The NGNN teamwas thoroughly impressed withthe tour of Medtronic, but wasreally blown away by Jerry’s highenergy, enthusiasm, and passionfor Lean.Jeff Colquitt conducted the tourof FRCSE. Again, the NGNNteam was duly impressed with allthat is going on at FRSCE on theThe NGNN team included,F-18 repair line. The team metGlenn Marshall, BenchmarkingMajor, the Operations Manager,and Sustainability Champion,Chris Street, Construction Super- another strong advocate of Leanintendent, David Scarlett, Refu- who demonstrated high energy,enthusiasm and passion for Lean.Glenn is also a long time mem- eling Planning Superintendent,Gray Milteer, Construction SuMark Grabynski gave the tour ofber of AME, Association forperintendent,andBobGranata,Goodrich Aerospace. This timeManufacturing Excellence. He isDirectorServiceandSupport,the NGNN team got a chance tocurrently leading the benchValue Streams Process Excelsee Lean applied in a low volume,marking sub group of AME.lence. These are the people that high mix manufacturing operaGlen wanted to accelerate thebuild and refuel nuclear powered tion. This is a similar operation toLean activities at NGNN andaircraft carriers. They are curthe NGNN operation of buildingasked me if he could bring arentlybuildingtheUSSGeraldaircraft carriers, and the team wasteam of executives to JacksonFord.able to learn a lot about how toville, to get more information onGroup visiting from NGNNStop Throwing Money Away,Give Your “Waste” a Second ChanceAn estimated 1.5 million tonsof paper is not recycled in Massachusetts per year. The estimated value, had the paperbeen recycled, would amount tomore than 100 million dollars.Many companies have decidedto use recycled goods to manufacture their products. For example, The book cover for thelatest Harry Potter book wasmade from recycled paper.It is estimated that 76% ofAmericans recycle! Waste Management Recycle America(WMRA) is hosting a LeanLeader’s Meeting in Orlando onAugust 27th in hopes of improving their current process and toallow JLC members to take abehind the scene look at whereour “waste” goes when its givena second chance.WMRA will be proving transportation and lunch for thisevent.Like the saying goes, “Oneman’s trash is another man’streasure”.(by Nicolle Beury)
The Lean GazetteHow many employees does ittake to screw I alight bulb?If a company identifies lightingas a waste and as a countermeasure they switch 25 incandescentbulbs to Compact FluorescentsLights (CFLs), which use 66%less energy, they can save 1,000 over the lifetime of thosebulbs. These bulbs also produceless heat and can result in lowerair conditioning bills. Lastly,these bulbs last up to 10 timeslonger so your employees canspend less time switching bulbsand more time on value addedwork.Page 2Lean and Green Make a Terrific PairLean and Green are the new Bradand Angelina. When used together these two snazzy concepts create an attractive couple.What makes Lean and Green sodesirable? They are both focused on the same goal - eliminating waste. As a result, combining the two efforts is a natural fit and can help to create asustainable organization andenvironment.As a Lean company you alreadyhave the perfect structure toidentify opportunities to improve your companies’ Greenprofile and save money.During a Lean event participantsactively search for and eliminatewaste. These wastes are brokeninto eight categories: Defects,identify these wastes during thisprocess can increase your environmental impact even more.The main categories to look forduring an event include physicalEnvironmental waste is often anmaterials, waste product, energy,elusive waste. It is hidden behindwater and air. Tracking thesethe scenes and is not at the foremetrics can help you calculatefront of all lean events, but ityour Green impact which canlurks behind everything that weoften translate into cost savings.do. When you eliminate defects,For example – how muchscrap and overproduction in amoney are you saving by reducprocess, for example, you are alsoing your electricity and watereliminating the associated enviconsumption or waste haulingronmental waste involved in profees?ducing these items (energy, water,materials etc.). So, decreasing or When you add Green to youreliminating many of these wastes successful Lean program it willresult in tremendous gains forcan automatically produce anyour company’s bottom line andenvironmental benefit.the environment paving the wayEducating the team about envito a truly sustainable future.ronmental wastes or Lean and(by Jodi Conway, Fla. DEP)Green and inviting the team toOverproduction, Waiting, NotUsing People, Transportation,Inventory, Motion and ExcessProcess.FRCSE Designated a New Commanding OfficerRECYCLE!A 60-watt light bulb can be runfor over a day on the amount ofenergy saved by recycling 1 poundof steel. In one year in the UnitedStates, the recycling of steel savesenough energy to heat and light18,000,000 homes!For more information aboutrecycling please visit: http://earth911.com/. Do your partand make an impact!It’s easy for all of us to live ourdaily lives and take for grantedour freedom; to be able to playgolf on Saturday afternoon, havea BBQ with friends, watch football on Sunday, or spend timewith our loved ones. There areover 200,000 men and womenoverseas who are serving for ourcountry. On July 10th, 2009 Mr.Rizzo, Faith Landis, and myselfwere invited to attend the Changeof Command Ceremony at FleetReadiness Center Southeast(FRCSE).FRCSE was established in 1940.In the past 69 years, FRCSE’sproduction shops have turned outnearly every type of Navy aircraft- fighter and attack planes, patrol,antisubmarine, reconnaissance,transport, trainer, special configuration, and helicopters. The overall workload for FRCSE has ex-panded to include the reworkof engines, components, andground support equipment,along with other support functions vital to the Fleet. Continuous improvement is practiced in daily operation processes, reduced costs are earnedby implementing Lean practices, eliminating “wastes”, andbecoming more efficient inoverall procedures dramaticallyimproved FRCSE process andthe overall operation of theirfacility.Former Commanding Officer CaptainTimothy S. Matthews receiving awardat Change of Command Ceremony.On July 10th, 2009 FRCSE appointed the new CommandingOfficer, Captain Paul A. Sohl. Hewas the Executive Officer atFRCSE prior to relieving CaptainTimothy S. Matthews, the departing C.O. at FRSCE. Captain Matthews has been recognized for hisoutstanding work throughout hisNavy career and has been nominated for Admiral.The service these two men havededicated to our country as wellas the other 2.5 million in ourmilitary is beyond reproach. Eachtime you see a soldier in uniformbe sure and shake their hands andsay “thanks”. Think if that wasyour son, daughter, mother, father, sister, brother or someoneclose to you; you want the samerespect for them. Congratulationsgentlemen and thank you servingour country! (by Nicolle Beury)
The Lean GazetteSpeaks Outafter HostingJLC’s FirstLearning Tour!“The Learning Tour was agreat way to address aproblematic process usinga quick one dayevent. Having outsidemembers on the teams allowed us to tap into theirexperiences and ideas,which is something that isnot possible with an employee only kaizenevent. For example, byimplementing a simple suggestion, the receiving areaoffloaded a container in 25minutes that would normally take 2 hours. Also,having to explain the process in detail opened oureyes into some of the areasand issues we didn’t noticebefore. The outside participants also walk away withideas and more experiencein Lean concepts. I thinkthe Learning Tour builds tothe strength of the LeanConsortium along with theimage of Pilot!” statedEric Brown, EngineeringManager at Pilot Pen,Participants brainstorming at Learning Tour“Special thanks to everyone who made this eventsuccessful along with thefollowing managers atPilot for being available!”— Juan Estrella —Director of Logistics,— Glenn Spilling —Customer Service Manger— Mike Stevenson —General Manager— Tim Witt —General Manager— Nick Galasso —Credits ManagerPage 3Quality Sign will Host This Month’s“Learning Tour”Have you ever passed up an opportunity because you felt it wouldn’tbe worth your time? Of course, wewould all plead guilty to this accusation!It is important to remember thatevery opportunity we have gives usthe ability to improve. Our response determines our growthfrom each experience.Makes me think back to my childhood when my parents were encouraging me to try new things. AsI got older and finally gave in Irealized I had been missing out ona lot of good things!The Learning Tour is not an eventyou want to miss out on! It is sucha unique opportunity to have atyour finger tips, and the experiencewill stay with you forever. Compa-nies generally hire in consultants toface problems and resolve issues.Together, as a Consortium, weunite to continuously improve.I am not begging any of you tosign-up and be a part of this event.I am simply making sure I emphasize the impact this event can haveon everyone who attends.New ideas are what generate innovation and innovation is what givescompanies a leading edge over thecompetition.Don’t let this experience pass youby. Join fellow JLC members onAugust 20th for the second Learning Tour (hosted by Quality Sign).Generate new ideas, open yourmind, and taste something different! (by Nicolle Beury)Follow theLearnerThe Role of a Leader in Creating a Lean CultureBy Dr. Sami Bahri, DDSDr. Bahri’s new book isnow available onwww.LEAN.org.Dr. Bahri is the first dentistin the world to implementLean. The Bahri DentalGroup is a member of JLC.Congratulations, Dr. Bahri,on your success throughoutyour Lean journey!Brady Corporation Specializes inVisual Workplace ConceptsBrady Corporation visited JLC onJuly 16th and JLC members filledour office! Brady is undertaking anationwide education program topromote understanding and use ofVisual Workplace concepts in leanmanufacturing. Brady Corporationis a label and identification company and currently holds 40% market share in the U.S. and is wellknown world-wide.Sustaining a Lean environment iswhat we all strive to achievethrough our Lean Journey. VisualWorkplace is a key requirement tocreate a Lean environment and is acore concept in the lean manufacturing toolbox. In fact, along withpractices such as 5S and StandardWork, Visual Workplace serves asone of the foundational elementsfor successful lean initiatives.Brady Corporation is also onboard for any of you whowould like them to help youcreate a visual workplace atyour company free of cost.They will come to your eventand help create visual controls for your workplace. Formore information contactFaith@leanjax.org(by Nicolle Beury)Lean Accounting/Cash Collection Workshop Will beOffered in SeptemberWhat if you could improve cashflow by shortening your currentcash collection process? Not justshortening cash collection byhours or days, but by weeks! JLChas invited Janice L. Frampton tofeature two workshops that willhelp greatly during this recession.“Improve cash collections withLean” and “Taking Action withLean Accounting” workshopswill be available September 17thand 18th. If you are faced withcash collection issues or are interested in strengthening youraccounting team by learning newtactics and practices in the field Iencourage you to attend. This isa great opportunity for a team towork on their current cash collections process with facilitationby a proven leader.To register, contact the Jacksonville Lean Consortium atFaith@leanjax.org . For questions, you may e-mail or call(904) 281-9026. We look forwardto seeing you there!(by Nicolle Beury)
The Lean GazettePage 4Learning Tour @ Pilot Pen - 07.07.09 Workingwith others from different companies is what I liked best.I learned the value of drawing out a front office process and analyzing thedifferent pieces. Creating a flow chart to help in decision making is a great idea that I want to take back to my own company! I loved the quality of the outside team members. They made significant contributions! This Learning Tour is a great way to motivate other employees!!! I loved the teamwork and different viewpoints. It was great to learn about the structure ofactually performing a Learning Tour as well. IMy favorite part was working with others from different companies.enjoyed the ability to critique a front office process through Lean. I learned that outsiders are healthy for your business! I liked the ability to work with others to increase my lean knowledge. I loved the motivation in improvement!Intro to Cont. Improvement @ FCCJ - 07.09.09 Very Informative!The practical application of the concepts was very helpful!My favorite thing was working in teams, being able to make suggestions. Great sense of teamwork. Sets a good example of how it can be used. Activities showed through own participation how changes affected the end result. Looking forward to coming to more classes!
The Lean GazettePage 5Lean for Office @ JLC - 07.21.09 Great class! I loved the whole process!I liked the hands-on activities & the multipleways of teaching.! Great class! Thirst for more!.My favorite thing was the personalcommunication from the Instructors I learned about streamlining, Kaizen and FIFOtoday. I will be using the concept of 5S and watchingfor the 8 wastes in my job now.I appreciated the focus on adminissues.As soon as I return to work, I’m going to color codemy projects & workload!Intro to VSM @ TBD - 07.22.09 I’m going to review our material handling as soon as I get back to work! Excellent class - thank you!I most liked using a real-life example to create a value stream map, and interacting with otherlocal professionals! I can definitely use what I learned about swim lanes and a continualimprovement plan in my job.I loved Mr Joe’s way of explaining! Thank you for the excellent opportunity to increase my knowledge of lean techniques!I liked the real life examples. Everyone was able to suggest their ideas!Intro to 5S @ JLC - 07.23.09 I liked the team projects.!I really enjoyed the activities!I plan to use 5S and the WorkZone website in my job. Great class!Very informative - Thank you!.Stimulating activities!I liked the interaction with the tasks.I will be using the 5S audit form in my job going forward, as well as the waysI learned to engage a team!
The Lean GazettePage 6Still Time to Sign-up!The Association for ManufacturingExcellence (AME), is North America’s premier organization for theexchange of knowledge in Organizational Excellence through the implementation of techniques such as Lean Tools, Leadership, Lean ProductDevelopment. This years’ 2009 AME conference offers new ideas andtools to help businesses improve and become more competitive in today’sdifficult economy. Change is coming and it is important to stay ahead ofthe competition in order to keep a competitive edge.Visit www.ameconference.org for more information. Contact JoeRizzo, Conference Chair 2009 AME Conference, at Joe@leanjax.org.The Director’s Chair“The JLC entertains executives from NGNN with two days of Tours”(Conti. Pg. 1)implement Lean in a low volume, high mix operation. Northrop Grumman also makes submarines and is Goodrich’s primecustomer. Goodrich is a primeexample of cells, 5S, visuals, metrics, self empowered teams andHoshin Planning, which is a newtopic for NGNN. The team wasawestruck at the degree of plan-ning and the selection of andcommunication of Corporateand Location goals and objectives.The last tour was of RexCorp., which represented ahigh volume, low mix operation. As you know, there is alot to see and learn at Rex. Assoon as the NGNN teamwalked into Rex, they knewJuly 15, 2009To:Joseph E. RizzoExecutive DirectorJacksonville Lean ConsortiumSubject: Benchmarking Trip of the Jacksonville Lean ConsortiumDear JoeOur team really appreciated you coordinating our benchmarking trip with your member companies of theJacksonville Lean Consortium. The fact that your consortium is a working model of a community partnershipwith businesses that are actively supporting “Enterprise Excellence through shared learning” and leveragingthat knowledge is an industry “best practice”.Our intent is to not only to share our findings within our company, but with the members of the VirginiaBusiness Excellence Consortium (VBEC). We would like to continue to leverage our learning by expandingour network to include your membership to promote ongoing exchanging ideas with our members.Just as your goal is to have a Jacksonville become a Lean City. We want the Southeast region of Virginia tobecome a Lean and Green Region. Looking into the future our goal would be to expand our VBEC Consortium System to 5 regional consortiums serving all of Virginia in becoming a Lean and Green State.Together our affiliation with the Association of Manufacturing Excellence is enhancing our capabilities toexpand our Learning Network not only in our region but across all of North America. We are firmly behindAME strategic initiatives to lead a Rebirth of Manufacturing and to create more Lean and Green Jobs inNorth America.Looking forward to working with you and member companies in the future on our collective journey to Enterprise Excellence through shared learning.Northrop Grumman groupvisits FRCSEthat they were touring something special. Bryan Berry gavethe tour and thoroughly impressed the visitors with explanations of and examples ofLean, Six Sigma, and Green.This year, Rex Corp. won theGreen Award from the USDepartment of Energy.After all the tours, I was concerned that the NGNN teammight have felt overwhelmedby the tasks ahead of them andthe time and resources required to catch up to the levelof the four companies thatthey toured. Instead, it openedtheir eyes to what is possible.They returned to NGNN withthe conviction and resolve ofknowing what they had to do.Benchmarking & Sustainability ChampionGlenn has offered a reciprocalvisit of Consortium membersto visit and tour the NGNNfacilities in Virginia. If anyoneis interested in touringNGNN, please let me knowvia e-mail or telephone.Founding Member of Virginia Business Excellence Consortium(by Joe Rizzo)Glenn MarshallNorthrop Grumman ShipbuildingDirector At Large for AME
The Lean GazettePage 7Lean & Green Certificate Classes are OfferedThrough JLC Under State Consortium GrantClasses are being offered toConsortium members at25% off the regular rate. Ifyou are not a member andare interested in attendingclasses you can still be approved and receive sign
The Bahri Dental Group is a member of JLC. Congratulations, Dr. Bahri, on your success throughout your Lean journey! Have you ever passed up an oppor-tunity because you felt it wouldn’t be worth your time?
