Identifying and Solving Problems using Visual Management
Alumicor is a Canadian based supplier of Architectural Aluminum building envelope systems. On this tour you will see how Alumicor has become a visual factory using visual management to drive improvements on the shop floor and in the office. Visual management boards measure Safety, Quality, Delivery, Productivity, Inventory and 5S. Production cells are color coded and material is pulled into the cells using visual cues. Employees chart hourly progress to plan on the visual management boards and identify challenges that are impeding their performance. Quick & easy kaizen, traditional Kaizen and A3 problem solving is then used to resolve the issues and continually drive improvement.
Simple replenishment process based on actual usage
Westeel manufactures steel storage products for the agricultural industry, as well custom storage solutions for the petroleum, biofuels and industrial sectors. Westeel has implemented Kanban/Faxban in several areas of the operation. On this tour you will see many of these Kanban systems and hear process experts share their experience with Kanban implementation. In Packaging, inventory was reduced by $1.1 million, space was reduced by 12,000 sq. ft. and the number of stock-outs reduced significantly. Kanban of coil steel has also reduced space required in the shop by 8,900 sq ft.
Rating: Beginner, intermediate
A process for large scale manufacturing transformation
In 2005 Loewen embarked on a large scale LEAN redesign of its door and window fabrication and assembly operations located in Steinbach, Manitoba. Using an approach developed in the UK and successfully applied by other leading manufacturers in Manitoba, Loewen completely redesigned the entire 600,000 sq ft facility into LEAN business units. On this tour you will see the results of this LEAN redesign and hear about the tools used to achieve a cultural shift and an increase in productivity of over 30%.
MacDon Production System
Agricultural equipment manufacturer transitioning to LEAN methods
MacDon Industries Ltd. is a family owned and Canadian based manufacturer of harvesting equipment specializing in the production of pull-type and self-propelled windrowers and specialty and pick-up headers for combines for world markets. On this tour, you will see a factory in a transition towards LEAN operations. ERP is the primary daily production execution system with LEAN methods overlaid and integrated. You will hear how Component Operations output is matched to Assembly Operations needs and how the Assembly Lines are balanced to flow, with efficiently designed workstations and Kanban-replenished materials.
MCI WPO (Work Place Organization)
MCI’s journey to LEAN
Motor Coach Industries is the number one supplier of tour, charter and line hail coaches in North America. On this tour, you will see the complete manufacturing cycle from parts manufactured to fully operational coach. You will hear how MCI continues to change with a focus on employees, customers and community. The tour will highlight how Kaizen events are helping make employees lives easier and safer. It will also include the Laser / Welding areas showing the development of kitting and one piece flow.
Applying LEAN Principles in the service sector
ImagineAbility Inc. (formerly Versatech Industries Ltd.) is a non-profit day service organization that provides a work environment, as well as job and recreational opportunities for people living with an intellectual disability. They also supply the business community with packaging and assembly services. The vision of the organization is that all individual are valued, accepted and can realize their potential. On this tour you will see examples of mistake proofing, visual management, Kanban and one-piece-flow. You will also hear how daily huddles ‘hive’ the people they support to improve processes through their suggestions.
Improve operational performance with common sense solutions
Magellan Aerospace is a global aerospace company that provides complex assemblies and systems solutions to aircraft and engine manufacturers, and defense and space agencies worldwide. In 2016, Magellan Aerospace Winnipeg started implementing Quality Clinics across the business. On this tour you will learn more about the Quality Clinics, a structured approach which uses cross-functional teams, brainstorming, root cause analysis, cost-benefit analysis and action tracking to thoroughly and efficiently solve real problems. You will hear how repeat issues have been solved and rework levels significantly reduced. The overall time to solve problems has been reduced and the effectiveness of corrective actions has increased.
Rating: Beginner, intermediate
LEAN Culture, LEAN Tools
Creating a LEAN culture
Argus Industries is a custom manufacturer of rubber molded products, die cut and CNC cut gaskets, seals and more, servicing markets from agriculture to aerospace across North America. Over ten years of “intentional culture” and LEAN tools has blurred the lines at Argus to what it means to be efficient, engaged and results driven. On this tour you will learn about the “Argus Tribal Culture”, but beware, this is not a formula, but a real-life example of how Argus has built their own tribe from the ground up. You will see how visual management and many other LEAN tools have found their way into creative solutions in the office and on the shop floor to ensure Argus is always on the leading edge of progress.
Rating: Beginner, Intermediate
From Kaizen to Business Unit Transformation
Transforming the Experience of Flight
StandardAero offers extensive manufacture, repair and overhaul (MRO) services for business aviation, commercial aviation, military and industrial power customers in more than 80 countries around the world. For almost thirty years, StandardAero has applied and refined its approach to business redesign, with 160 LEAN Cellular transformation programs todate, achieving sustained STEP-change (TM) performance gains. Through these transformations, StandardAero has driven improvements in turn time, labor efficiency and product quality to industry-leading performance levels. On this tour, you will see the MRO flow of the GE CF34/CFM56 aero engine that includes visual electronic production/tracking boards, line balance and systems that improve processes based on the "voice of our customer".
Operational Excellence in Healthcare
The St. Boniface Hospital journey to perfect patient care
The St. Boniface Hospital is a Catholic teaching facility founded by the Sisters of Charity of Montreal. Founded in 1871, the St. Boniface Hospital continues to be a pioneer in health care. The tradition of caring and reputation for leadership, flow directly from the Grey Nuns’ belief in “taking action to care for those who come in need”. On this tour you will learn about Operational Excellence at the St. Boniface Hospital and its pursuit of measurably better value for patients. You will see the daily management system and strategy deployment system used to drive towards everyday ‘operational excellence’.
Journey Through the Boeing Production System
Empowering to build a culture of change. Transforming the Experience of Flight
Boeing Winnipeg is one of the largest aerospace composite manufacturers in Canada, producing composite parts for Boeing 737, 747, 767, 777 and 787 airplane models. On this tour you will hear about the four stages of implementation of the Boeing Production System. You will see efforts made throughout the factory, in conjunction with the support organizations, to implement a production system that emphasizes employee engagement, systematic problem solving and a culture of continuous improvement.
Delivering Excellence through Continuous Improvement and Innovation
Opened in 1976, the Royal Canadian Mint Winnipeg location produces circulation coins for Canada and other countries around the world. Production of coins requires high-speed, high-volume processes including blanking, electroplating, coining and packaging. On the tour of this 225,000 sq ft facility, you will see a number of continuous improvements including 5S, huddle boards, visual management and single-piece-flow implementation. You will also see innovative processes such as the high-speed paint line and R&D Centre of Excellence.
Our journey from batch & queue to flow production
Custom Castings began its Lean journey with the implementation of a structured 5S program. With processes organized, the need to change from batch & queue to flow production became very evident. In 2015, a project was launched to transition to cellular manufacturing. All of the major value streams were mapped to define cells that would allow work to flow from molten metal to finished goods with minimal changes of ownership. On this tour, you will hear about the challenges and successes of this multi-year project, about SMED and TPM implementations, cross-training and the importance of buy-in and support from all employees.
Cultural Engagement Tour
Sustainable Growth Through Employee Empowerment
The Duha Group creates color marketing tools like paint chips, fandecks, and color systems that help customers bring life to beautiful spaces around the world. On this Cultural Engagement Tour, you will witness the Duha Operating System, viewing successful lean initiatives on the shop floor and in the office and learning about the 4 key steps that the Duha Group experienced on their Journey to Lean; the Passport to World Excellence System; the 5 minute Daily Huddle System; the 12 Step Turbo Kaizen System and Organization Balancing, which helps to balance the flow of materials and information.
Rating: Beginner, Intermediate
New Flyer Operational Excellence Program
The Op Ex Journey
New Flyer is the largest heavy-duty bus manufacturer offering the widest range of drive systems in North America. On this tour, you will hear about the application of LEAN principles at the Winnipeg Assembly Plant as part of the Operational Excellence strategy and how applying LEAN to manufacturing and other life cycle processes is delivering value to the customer and revenue to the enterprise. Touring the vehicle assembly line and primary component manufacturing areas you will see cell support teams, 5S implementation and visual factory concepts including takt timeline move boards, ANDON system, TPM and the proprietary Livebus production verification system.