1 / 24

2012 Employee Town Hall CRT Report Out

2012 Employee Town Hall CRT Report Out. Production Metrics Safety Strategy Deployment Value Stream Projects Lean Efforts Plant upgrades. Ink Production . Dispersion- Manufacturing. YTD – 12.4 Million Pounds 37% increase over last year. 3 Roll Mill Yellow into storage tank

bazyli
Télécharger la présentation

2012 Employee Town Hall CRT Report Out

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. 2012 Employee Town Hall CRT Report Out • Production Metrics • Safety • Strategy Deployment • Value Stream Projects • Lean Efforts • Plant upgrades

  2. Ink Production

  3. Dispersion- Manufacturing • YTD – 12.4 Million Pounds • 37% increase over last year. • 3 Roll Mill Yellow into storage tank • 8.1 Million pounds of dispersion vehicle

  4. Varnish Manufacturing • 18% Increase YTD over last year. • 29% increase in structured varnish. • 16.5% decrease in non structured varnish • Significant shift to retail ink = more clay base, more structured varnish. • Retail ink uses less manufactured varnish overall.

  5. PMS, Fountain Solution, and MISC.

  6. Safety Measures • First Quarter 2012 Dart rate 3.37 • Dart rate is important for tracking incidents and injuries more importantly dollars and cents make the biggest difference. (Days Away, Restrictions, and Transfers) • CRT Work Comp 2011 $5,134.58 • CRT Work Comp YTD 2012 $33,264.00 • Work safe.. we’re trending in the wrong direction • Quad would need $1,000,000 in sales to make up the YTD Work Comp, just to break even.

  7. Strategy Deployment Value Stream Mapping Quad Lean Q “use the collective thinking power of all employees to make their organization the best in its field." -Professor Kaoru Ishikawa

  8. Quad/Graphics' Mission Statement • We are a value driven company committed to our clients, employee owners, shareholders, communities and the environment. • As the industry leader, we take print to a higher level through service, quality and technological innovation. • We will grow profitability as the high value, low-cost producer.

  9. Strategy Deployment • Focus on a shared goal • Communicate that goal to all leaders • Involve all leaders in the planning to achieve that goal. • Hold each other accountable to achieve their part of the plan

  10. Strategy Deployment • Long Term Goals • Secure Raw Materials at the highest quality, lowest price. (RFP) • Digital Inks – Ink jet • Mexico and South America will utilize CRT Products • CTO – TOR trade for finished Resin • Adhesives • Quick Hits (now) • Wax Manufacturing • Clay base Manufacturing • 3 Roll Mill Yellow • Remove toner from Black Ink • Fountain Solution • OPV • National GEO Inks

  11. Combined Wax Manufacturing $2.9 Million Savings • CapX: $1.2 Million • Fast Track Wax Production: April 1st-$506,000 Savings • Full Scale Production Using Molten Wax Storage Process System Original Completion Date: July 1st, 2012

  12. Dry Pigment Volume Capitalization $800k Savings (end of 2nd quarter) • Ongoing Quarterly Project • $300k 1st Quarter Savings • $500k 2nd Quarter Savings (increased savings due to new supplier) • Minus Carbon Black Increase Due to Natural Gas and Oil Market

  13. Fountain Solution Scale Up • Projected Completion Date: July 1st, 2012 • Original Completion Date: July 1st, 2012 • CapX: $419k – On Target • Initial Fountain Solution Production Adds Additional $95,000 Savings • 10 Plants Using Fountain Solution 100% • Some reformulations • 2804 no longer • 2805 work horse product • 2801 Manrolands - Hartford

  14. Manufacture Clay Base $436k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 13th, 2012 • CapX: $228k – On Target • Full Scale Production Delayed 2 Weeks • Clay Conveying System Needs Additional Work Due to Complexity of Clay Particle Size (must be correct) • Potential for Additional Savings for Using a Less Refined Clay

  15. Manufacture National Geographic Cover Inks $185k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 1st, 2012 • Preliminary testing was good, need 1 additional test to move forward. • Additional Savings Due to Saratoga Also Using Ink Series

  16. Manufacture Overprint Varnish $97k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 1st, 2012 • CapX: $25k – On Target • Raw Materials for Testing are Procured • Overprint Varnish is Manufactured • Tested in Sussex – slight formulation change needed • Additional testing

  17. Remove Alkali Blue $1 Million Savings • Original Completion Date: July 1st, 2012 • Formula is Created and Ready for Release to Production • Currently There Are No Standards for Plate Curves (Bob Hallam is Working on) – Test complete 6/07

  18. Supply Sheetfed Ink $1 Million Savings • Projected Completion Date: July 1st, 2012 • Successful Ink and Fountain Solution Test in Dubuque • Currently Testing of Different Packaging • When Additional Sheetfed Ink is Rolled Out, Fountain Solution Will be Included • UPDATE – New Berlin, Dubuque, Burlington, and Waukee successfully running this ink 6/8

  19. Yellow 3 Roll Mill $700k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 30th, 2012 • CapX: $200k – On Target • Purchased Used Mill from Germany • Will Arrive in New Jersey Week of March 12th • Buhler to Refurbish to ANSI Standards and Deliver to CR\T by May 15th, 2012 – Last week of June • All Material Needed for Base at CR/T • Project Ahead of Schedule – 4 weeks behind

  20. Value Stream Event and Planner • Production road map for the improvement cycle.

  21. Improvement Metrics

  22. Lean Events YTD • Value Stream Mapping Event – 1/20/2012 • Review Standard Work (Ink) – 2/1 – 3/1 • Citdel Process Detail Event – 2/20/2012 • Operator Balance Event – 4/05/2012 • RCA Class – 5/10/2012 • 6-S Compound Pit – 5/14/2012 • Etch Standard Work – 5/25, 5/30 • RCA Class – 6/5/2012 • 6-S East Docks – 6/25/2012

  23. Building upgrades • 200 HP Boiler being installed late summer. • New AC Unit on Building one being installed early July. • Last 24 months Quads invested over $4 Million at CRT Hartford.

  24. Any Questions?

More Related