- Argus Industries
- Boeing Canada Winnipeg
- Canada Post
- Custom Castings
- Duha Group
- Emergent BioSolutions Winnipeg
- JELD-WEN Windows and Doors
- Loewen Windows and Doors
- MacDon Industries
- Motor Coach Industries
- New Flyer
- Royal Canadian Mint
- St. Boniface Hospital
- Winpak Division
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.
Rating: Beginner, Intermediate
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’.
CONTINUOUS IMPROVEMENT TRANSFORMATION
Agricultural equipment manufacturer APPLYING LEAN PRINCIPLEs
MacDon Industries Ltd. is a Canadian based manufacturer of harvesting equipment specializing in the production of headers for combines as well as pull-type and self-propelled windrowers and specialty pick-up headers for world markets. On this tour, you will see the implementation of various LEAN initiatives through all stages of production and assembly, including 5S, Kanban materials, Vendor-Managed inventory and Takt time flow. You will hear about recent improvement initiatives to reduce shop floor inventory and improve shop floor layout and learn about some of the successes and challenges of transitioning an improvement program through different levels of maturity.
JELD-WEN Excellence Model (JEM)
JELD-WEN is one of the world’s leading manufacturers of windows and doors. The Winnipeg operation is the only JELD-WEN facility that produces windows, exterior doors and interior doors all on one site. On this tour, you will learn about "JEM", a collection of LEAN manufacturing tools and process improvement techniques that engage associates at all levels and enables JELD-WEN to achieve operational excellence. You will tour glass unit (IGU) production and window and door assembly and see the various elements of the ‘closed loop’ shop floor visual management system; the hour by hour production boards, KPI tracking boards, basic problem solving and Gemba walks.
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
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
AGI-Westeel manufactures steel storage products for the agricultural industry, as well custom storage solutions for the petroleum, biofuels and industrial sectors. AGI-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
Operational Excellence in a Biotech Environment
The Journey to Excellence Through Hoshin Kanri
On this tour, you will see the principles of LEAN applied in a highly regulated and segregated environment. Learn how Emergent BioSolutions Winnipeg is guided by Hoshin Kanri - LEAN Strategy Deployment - and applies LEAN concepts in an environment where changes must be closely controlled and reported to regulatory agencies. Emergent BioSolutions is a global life sciences company focused on providing specialty products for civilian and military populations that address accidental, intentional, and naturally emerging public health threats. Through our vision to protect and enhance 50 million lives by 2025, we will give millions of individuals the opportunity to experience the fullness of life. Emergent Winnipeg has a 50-year history of manufacturing lifesaving countermeasures, hyperimmune plasma products, and products to address emerging health threats.
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.
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
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.
From Continuous Improvement to Business Unit Transformation
Phoenix Rising Up from the Ashes
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 to date, 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. One example of this is our SACS Canada Component facility which suffered from a huge fire in the fall of 2014. On this tour, you will see extensive use of visual systems, cellular design, point-of-use materials, electronic production/tracking boards, 5S, line balance and systems that improve the process based on the “voice of the customer”.
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.
Lean and New Technology
Continuous improvement and new technology go hand in hand
Winpak Division operates ten production facilities across North and South America, manufacturing high-quality, food-safe packaging materials and products for the pharmaceutical and healthcare industry. Plain and printed materials are converted into either rolls or pouches. The 500,000 square foot Winnipeg facility employees over 750 people. On this tour, you will see how Winpak continues to invest in new technology to stay at the forefront of the industry, while at the same time embracing LEAN concepts to ensure that continuous improvement is a key part of the strategy. Tour highlights include engagement of employees in finding a better way ... every day, utilization of 5S and visual management as a problem-solving tool, implementation of robotics to improve flow and efficiency and communication systems to ensure a consistent message is heard across the organization.
Canada Post Winnipeg Mail Processing Plant
Moving to the Modern Post
The Winnipeg Mail Processing Plant was the first new Canada Post facility in two decades. On this tour you will see how mail is moved to meet the organizations’ mandate to reach Canadians everywhere…everyday... You will see a mixture of automated equipment and processes to flow mail. Highlights include the use of visual management and packet/parcel automation and logistics.
Rating: Beginner, Intermediate
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.
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%.