May 2012 - Cpk Interior Products

May 2012
The Compass
Issue
TEN
In 2011 we accomplished or exceeded all of our goals. None of these is more important
than our Safety record and statistics. Understanding that numbers or statistics represent employees getting injured or hurt on the job, it is this that we want to improve or
eliminate. We need to protect our greatest asset—“people”.
We made many improvements in safety such as updating our pedestrian walkways, improving our visual factory, identifying our model area, the introduction of unsafe acts, unsafe conditions and near miss reports to just name a few.
Safety is the first pillar and the most important pillar in WCM and rightfully
so. I have many goals this year but none more important than to continue to
improve Safety throughout the organization. Last year we finished with 0
lost time injuries, 12 recordables and 41 first aids.
Please work safely, continue to report unsafe acts and unsafe condiOUR Mission:
tions and understand you have the right to refuse to do any job or
To be the standard by which all inteoperation that you feel is unsafe! Togethrior products companies define
er we will make our workplace free of injuthemselves — globally admired for
ry!
our people, partnerships, quality
and innovation.
Plant Manager Message
1
WCM Plant Lead Message
1
Early Equipment Management
2
Welcome & Anniversaries
3
Face of Change (February)
4
Face of Change (March)
5
Suggestion Program Update
6
Brain Teasers & Chrysler Advantage Program
7
Community Involvement
8
Mission Zero Challenge –Environment Winners
10
Mission Zero May Challenge—Logistics
11
Principles of Safety Heinrich
12
Safety: Something to Think About
13
Wellness Corner
14
WCM: Change is Good
15
WCM: Route Map & Application of WCM
16
OUR VISION:
To have a fully engaged workforce dedicated to the
principles of World Class Manufacturing, leading by
example through:

Cultivating a completely safe work environment;

Meeting and exceeding customer expectations
and requirements;

Driving out waste from our operation
WCM is the road map we will use to become the best
Interior Component Company in the world, most admired for our people, partnerships, quality and innovation.
We have acquired new business from a
company called ACH and we are now
launching shell production for the Ford Focus program. Due to high sales on this vehicle an additional shell supplier was needed and that’s where we came in. We will be running 4 shell nickels
over 3 shifts. This additional work has driven us to require mods to
be run on all three shifts. This program began in April and will run
for ten months. This marks the first business outside of Chrysler that
we have obtained since becoming CpK.
Thank you to all who have been involved in launching this program
in such a short time. We always deliver even under pressure and
come out successful! This program will be no exception.
Tim
WCM THOUGHTS...Sometimes it takes someone from the
outside to hit an issue home and this was the case Wednesday, April
25th. We had the opportunity to have Mauro Pino, Chrysler’s Head of
WCM — NAFTA, and his team visit and review our facility. The feedback provided was very positive; he challenged us to learn, apply and expand
WCM quickly and effectively ensuring sustainable results.
During the PM board review Mauro Pino took off his safety glasses. At the closing
of the meeting he comment on the fact that no one had spoken to him regarding
his lack of PPE.
I’m sure that we could all come up with a reason we didn’t, but then we’d be
missing the point...Safety has no boundaries! It is our responsibility that if we
see it, we correct it immediately if possible or report it to the appropriate personnel for correction, after all…………………………….. SAFETY MATTERS
Page 2
EARLY EQUIPMENT MANAGEMENT
To continue to be successful in business and meet the many challenges that our industry faces today, it is crucial that we apply the methodologies of Early Equipment
Management (EEM). The focus of this pillar is to incorporate the experience of all
pillars in developing low cost equipment that is safe, reliable, maintainable, and production ready in
minimal time (vertical start-up).
Jim Horner
Product Engineering
Manager
To do this, information about problems on our current equipment and tools must be continuously collected through many sources, including SEWOs, EWOS, Kaisers, Work Orders, Lessons Learned, and
documented on an MPI (Maintenance Prevention Information). This form describes an issue/solution regarding a
problem with a piece of equipment and drives a checklist question that is asked during the development of new equipment. The goal is to ask most of the questions upfront during the early planning stages, thereby reducing the initial
cost and lead-time.
When purchasing new equipment, we can pull up the machine category and transfer the information from the MPI
form, including the checklist questions, into specifications that improve the machine’s safety and environmental function as well as others.
Like all other pillars, EEM has key activities that are measured to drive improvement and these are “number of MPI
Forms created” and “number of Checklist Questions reviewed”. During our first WCM audit, the auditor commented
that we should be targeting the development of over 10,000 checklist questions.
We are aware that this will not happen overnight and ask that we keep the information flowing utilizing the MPI form.
This will enable us to lower equipment life cycle costs (LCC); improve our business performance and manufacturing
capabilities thereby making CpK Interior Products more competitive in a challenging industry.
THE MPI form can be found on the WCM Information Centre under Forms.
“When one door closes, another one opens; but we so often look so long and so regretfully upon the closed door, that we do not see the
ones which open for us.” Alexander Graham Bell
Page 3
Welcome to the following employees who have recently joined the Cpk Team:
McKenna Ainsworth
Tyler Alexander
Heather Allinson
Rick Baldini, Process Engineer
Craig Bradley
Kurt Brown
Katelyn Buck
Mike Coull
Tyler Croll
Bryan Curtis
Justin Galloway
Scott Giddings
Joceylnn Gillespie
Mike Johnston
Sara Kort
Emily Laidman
Jennifer Mabee
Ryan Markle
Chantelle Niles
Ashley Nobes
Peter O’Sullivan
Matthew Russell
Chris Sexsmith
Jennie Sovie
Kristian Thomas
Crystal Thompson
Mike Thompson
Jill Walters
Scott Wood
Congratulations!
to the following employees for celebrating milestone anniversaries with the Company:
40 Years
35 Years
30 Years
25 Years
Linda Miller
Carol Harrison
Donna Currin
Millie Bell
Jerome Ward
Doug Woodward
Donna Cole
Colin Johnson
Lillian Catherwood
Jackie Dallas
Jeff Gill
Ron Roddy
Tim Roddy
for
Dianne Huffman
on
SUNDAY, MAY 6, 2012
from
2:00 p.m. to 4:00 p.m.
at the
DURHAM MEMORIAL TEMPLE
(Oddfellows Hall)
HWY. 28, PORT HOPE
Page 4
INNOVATION...INGENUITY...INVOLVEMENT
Thank you to everyone who made a difference in the month of February and contributed to our
Employee Suggestion Program. Congratulations to the following individuals for each winning the
monthly awards and a $25 gas card in the following categories:
Jacky Spicer
Bob Bullock
For her suggestion and contribution in
the area of Environmental Improvement within our Workplace.
For his suggestion and contribution in
the area of Safety within our Workplace.
WCM Parking Spot Winners
The winners of the four WCM parking
spots were determined from all those
who submitted a suggestion in the
month that their name was drawn.
March Winners: Lorraine Hall, John
Saunders, Cameron Potts and Robert Andrews.
April Winners were: Kathleen Fowler,
Meredith Walker, Shelley Soos
May Winners are: Marion
Windsor, Bob Hassell,
Crystal Cole and Larry
Reid
This Month’s Spotlight shines on...
Page 5
INNOVATION...INGENUITY...INVOLVEMENT
Employee Suggestion Program FACE of CHANGE MARCH Winners
Thank you to everyone who made a difference in the month of March and contributed to our Employee Suggestion Program. Congratulations the following individuals
for each winning the monthly awards and a $25 gas card in the following categories:
Pat Fox
For his suggestion and contribution in
the area of Environmental Improvement within our Workplace.
Doug Murray
For his suggestion and contribution of
WCM Spirit throughout the Organization. Doug’s suggestion was related to
improving a work area to allow for better
visual inspection.
Trevor Stevenson
For his suggestion and contribution in
the area of Safety within our
Workplace.
Willemina Ludyka
For her suggestion and contribution in deploying Creative Thinking throughout the Organization. Her suggestion was related to eliminating the need to store shells in the tool to protect them which will eliminate wasted energy to
preheat mod to remove shell at start-up.
When the best things are not possible, the best may be made of those that are. - Richard Hooker
Page 6
Employee Suggestion Program Update
“The major reason for setting a goal is for what it makes of you to accomplish it. What it makes of you will always
be the far greater value than what you get.” Jim Rohn
Page 7
BRAIN TEASERS
Test your Brain Power!
Ready to give your brain a little exercise? See if you can solve the
brain teasers below. Good Luck! (Answers below)
1. You have a 3 gallon jug and a 5 gallon jug. You need to measure out exactly 7
gallons of water. How do you do it?
2. Count the “f’s” in this passage FINISHED FILES ARE THE
RESULT OF YEARS OF SCIENTIFIC
STUDY COMBINED WITH THE
EXPERIENCE OF YEARS
How many did you count?
You don't have to be great to start, but you have to start to be great. Zig Ziglar:
New Contest
Tell us if you have taken ADVANTAGE of the Chrysler Advantage Plan during the period of April
1st, 2012 to June 30th, 2012 for your chance to win a $25.00 Gas Card. Send an email to
cathy.klein@cpkip.ca or leave a message at 905-885-3526. Please provide your name, shift, supervisor and the date and type of vehicle that you purchased.
GOOD LUCK!
2. There are 6 “f” in this passage. If you only counted 3, you’re not alone. Most people fail to
count the “f’s” in the word of. Why? When looking for “f’s” your brain is actually scanning
for the sound of the letter “f” - which usually makes the /f/sound, like in fox. In the word of,
though, “f” makes the /v/sound. As a result, the brain overlooks the word of as it scans for
the sound /f/.
1. Fill the 5 gallon jug with water, pour into the 3 gallon jug until the 3 gallon is full, leaving 2
gallons in the 5 gallon jug. Now pour out the water in the 3 gallon jug. Pour the 2 gallons of
water (in the 5 gallon jug) into the empty 3 gallon jug. Fill the 5 gallon jug. You now have exactly 7 gallons!
Answers:
Page 8
Innovation….Ingenuity… COMMUNITY Involvement
Thank you to everyone who purchased raffle tickets to win the Easter Baskets. We raised $ 431.11 which
went towards our United Way campaign. The winners of the baskets were Joan Byers and Darlene Calder.
Habitat For Humanity
Build
Never doubt that a small, group of thoughtful, committed citizens can change the world. Indeed, it is the
We are looking to put together
only thing that ever has. -- Margaret Mead
a team to help with an upcoming Habitat for Humanity
build on Harcourt Street in
Port Hope.
If you would like to volunteer
for a Saturday in early May
and be part of the CpK Team
please let either Michelle Garrard (ext. 527) or Cathy Klein
(ext. 526) know or sign up on
the sheets located on the
boards near the East & West
Employee Entrances!
Do you or someone you know do great things in the community? We want to hear from you. Drop us a line and let us know if you know someone who is
Making a Difference!
Page 9
If you are participating in a community event outside of work and would
like help communicating it, please call Michelle in Human Resources at ext.
527 so that we can ensure the information gets posted on our boards.
Innovation….Ingenuity…
CANCER AWARENESS DAY
COMMUNITY Involvement
A Huge Thank You!
Thank you to everyone who dropped off
their gently used clothing in the month
of January. As you can see we donated
a lot of clothing to the Northumberland
Women’s Shelter and what they couldn’t
take we donated to the Big Brother’s Big
Sister’s Northumberland Office. Not only
did we help others in need, we cleaned
out our own closets!
We DO Make The Difference!
Thank you to everyone who purchased pancakes, daffodils and pink ribbons on Thursday, April 26th, we raised
$700.00. All proceeds
will go to the Canadian Cancer Society
One blood donation
can save up to three lives.
If interested in giving, check
out the Community Involvement
Boards to find out the next date
and place to give blood.
Thank you to everyone who
dropped off non-perishable food
items to our Easter Food Drive.
We donated 116 pounds of food
to the Food 4 All Warehouse
which distributes food to Northumberland County.
We make a living by what we
get, we make a life by what
we give.
- Sir Winston Churchill
Page 10
s
r
e
n
n
i
April W
Congratulations to the Winners of the April Mission
Zero Challenge!
We had a TIE!
The winning line/areas of the Mission Zero Cup and a
Pizza Lunch are the
1st Shift LC Challenger
and 2nd Shift LX Doors
It was a very close race and thank you to everyone for
doing your part for the environment!
"Listen up, you couch potatoes: each recycled beer can
saves enough electricity to run a television for three
hours." ~ Denis Hayes
Page 11
1.
Find a Logistic Loss from any area of the plant and submit it using
the provided forms (which you can obtain from your supervisor).
2.
The Area with the greatest quantity of identified losses will win this
month’s pizza lunch and the Mission Zero Cup!
3.
All submissions can be dropped off in the Suggestions Boxes located
outside the Nurse’s Station or in the WCM Area
Examples of Losses
MISSION ZERO CHALLENGE
MAY’S
Group 1:
Group 2:
Group 3:
Group 4:
Group 5:
Group 6:
Group 7:
Group 8:
Group 9:
Group 10:
Group 11:
Group 12:
Group 13:
Group 14:
Group 15:








Scrap Not Reported
Parts Not Labelled
Hold Products
Quantity of Inventory Line Side
Rework - Sorting - Repack
Parts not labelled
Walking materials throughout the plant.
Equipment that does not belong in an area
1st Shift
Injection Operators, Defroster Grille, Technicians and Injection Tooling
LX Console Line (incl. Technicians and Inspectors)
LX I/P Line (incl. Technicians and Inspectors)
LC Challenger, Service/Service Pack (incl. Technicians and Inspectors)
LX Doors (incl. Technicians and Inspectors)
Maintenance, Projects, HVAC, Electricians, Modular Tool Specialists
Environmental, Janitorial, Compounders, Distribution/Warehousing and Inventory
Control Analyst
Colour & Analytical Lab, Quality & Dimensional Auditors, Tech Development, Auto
mation Techs, Pour Mold Tooling & Coating Set-Up
2nd & 3rd Shift
Injection Operators, Defroster Grille, Technicians and Injection Tooling
LX Console Line (incl. Technicians and Inspectors)
LX I/P Line (incl. Technicians and Inspectors)
LX Doors (incl. Technicians and Inspectors)
Maintenance, Projects, HVAC, Electricians, Modular Tool Specialists
Environmental, Janitorial, Compounders, Distribution/Warehousing and Inventory
Control Analyst
Colour & Analytical Lab, Quality & Dimensional Auditors, Tech Development, Pour
Mold Tooling, Automation Techs and Coating Set-Up
Page 12
PRINCIPLES OF THE HEINRICH PRYAMID
Is SAFETY NUMBER 1?
The implementation of the reporting of “Unsafe Acts, Conditions and Near Misses” has certainly raised considerable activity within our facility. As a result, it is important to take the time to understand the Heinrich
pyramid as it is the key to achieving “MISSION ZERO”.
The Heinrich Pyramid is built as follows:
1 Fatality
30 Lost Time Injuries
300 Minor Injuries
Statistics have shown that for every 1 fatality
there should be a number of corresponding
injuries, unsafe acts and conditions
Our 2011 and YTD 2012 statistics are as follows:
YTD
JAN
FEB
Fatal
0
0
0
Recordable Injury
(Severe S-54 & LTI
> 30days)
0
0
0
Recordable Injury (0 days < LTI
≤ 30 days)
0
0
0
Recordable
2
1
1
First aid
7
5
2
Near Miss
3
2
1
Unsafe Condition
174
74
100
Unsafe Act
12
4
8
30,000 Unsafe Acts &
Conditions
Near Miss: An event that under even slightly different circumstances could have lead to an injury.
Unsafe Condition: Any condition not caused by a
human (i.e. environment, machine) that could
lead to an injury.
Unsafe Acts:
Any human related action that could lead to an
injury.
As an organization we are committed to achieving “ZERO”, it will take
the entire organization to build a new pyramid without lost times, severe injury, recordables or first aids. The way to achieve this new pyramid is to continue to identifying Unsafe Acts , Unsafe Conditions and
Near Misses and correct them appropriately at a plant wide level.
Page 13
SAFETY: SOMETHING TO THINK ABOUT
Safety is in our lives every day. Everywhere we look safety is all around us; our homes (with smoke detectors), in the general public (posted speed limits), and of course, in the workplace. So, in a sense, safety is
always touching our lives.
Safety is not a complex mathematical equation, it’s common sense. For example, if your friend or family
member is about to walk into on-coming traffic, would we not reach out to them and pull them back to
safety to ensure that they are not hit by a car? Well, of course we would. It just makes sense.
In every injury, there are (usually) multiple Unsafe Acts/Conditions that will contribute. It is important to
understand that by eliminating Unsafe Acts/Conditions, we in turn, eliminate the hazard(s) that causes the
injury. That is the goal of the identifying and correcting Unsafe Acts and Conditions; Injury Prevention.
The perception of identifying Unsafe Acts/Conditions has been defined by some as “ratting” out people
and it is upsetting to think that looking out for your friend or co-worker is considered such. If we think
back to the friend or family member crossing the road and pulling them
back to safety—we are doing so because we care and they would likely
thank you, and feel you are just looking out for them, ensuring they are
not injured. Why wouldn’t we think the same way about preventing injuries at work?
Remember safety is about you and me (us). Our families depend on us to
come home the same way we went to work.
Let’s work together to make this happen.
Page 14
Mauro Pino, Chrysler Head of WCM for NAFTA—Coaching Visit on April 25th, 2012
Mauro Pino and the group at the PM
Model Area
Mauro Pino and Pillar Leads in a coaching session
in the Crosby Room
PM Board
Review with
Mauro Pino
Pictured below John Hebel, Doug
Murray, Tyler Roffey and Randy Ellis
John Hebel, Powertrain World Class Manufacturing Specialist provided coaching
assistance to our Professional Maintenance Team
Pictured above Gayle McKeen, Randy Ellis, John Heble, Doug Murray and Tyler Roffey
WCM Training
Centre now
located on the
Console Line
Page 15
We are scheduled to have 2 Internal WCM audits this year (May/November). Our first audit is scheduled for the week of May 28th
and we are targeting a score of 21 (9 Technical, 12 Managerial). If you would like to know more about the audit and the audit process, please drop by the WCM office.
Some people want it to happen, some wish it would happen, others make it happen……….Michel Jordan
Perseverance and determination…
The Ganaraska River that runs through the heart of Port
Hope provided the inspiration for our visual depiction of CpK
Port Hope’s application of World Class Manufacturing.
It is instinctual and a part of a salmon’s DNA to run for the
top. The fish are focused on the survival of the species and
therefore are driven, regardless of obstacles, to meet whatever
challenge lies ahead.
We have been brought to the base of the fish ladder through
the perseverance and determination of the many generations
of our workforce. Through the application of World Class
Manufacturing methodologies and tools we will run to the top. Thereby, ensuring our continued success in an
extremely challenging and competitive marketplace.
…the spirit of CpK Port Hope Interior Products
Page 16
WELLNESS CORNER
Healthy Body Images - A Positive Way to Look at Yourself
Body image is the mental picture you have of your body plus the feelings and judgements you have about this
picture. This picture is often very inaccurate and has little to do with how you actually look or how other people see you. With positive thoughts and lifestyle choices you can change you body image and how others respond to you.
Ten steps for building a positive body image
1. Accept yourself. Feeling good about yourself starts with accepting who you are and how you look. Healthy bodies come
in all shapes and sizes. Focus on your good qualities and pass over any negatives.
2. Step off the diet roller coaster - for good. Dieting brings temporary weight loss, but 1/3 to 2/3 of the weight is usually
gained back in the fist year. Almost all the weight is gained back within five years and sometimes much more. The cycle
of losing and gaining can be harmful to you health and it can lead to frustration, anger and an even poorer body image.
So, stop dieting. Instead, eat well and enjoy being active.
3. Enjoy eating well. Eat for energy and for pleasure. Follow Canada’s Food Guide to Healthy Eating. Choose more grains,
pasta, legumes, fruits and vegetables. Choose lower-fat dairy products, leaner meats and foods prepared with little or
no fat and see how good they taste. Don’t worry about having chocolate once and a while. The trick is to only "indulge"
once in a while! Think of balancing what you eat over the day or week and remember that moderation is the key.
4. Enjoy being active. How about a noon-time walk, a family hike or a swim with friends? Physical activity lets you enjoy
the outdoors and helps you deal with stress while making you feel more energetic.
5. Create a mental spa. Breathe deeply and relax. Doesn’t it feel good to slow down and let go of your responsibilities for
a while? Experience the magic when you quiet your mind and let yourself enjoy the stillness.
6. Make your imagination work for you. Everyone has 5,000 thoughts every hour! Use your imagination to practice attitudes you want in your life.
7. Look your best always. How you keep yourself shows how you feel about yourself. Wear clothes that fit and give away
the ones you never wear. For fun, try a new hair style, tie on a scarf or indulge in a new pair of earrings. And remember
to smile. It gives you and everyone you meet a real boost.
8. Get support from family and friends. Ask for help when you need it. Organize a group of friends or find a buddy and
help each other meet your goal to be the best that you can be. Think of ways to create lots of fun and laughter for each
other.
9. Be thankful. To take your mind off negative thoughts, make a list of 10 things that give
you pleasure and keep this where you can see it. Make another list of the beautiful aspects of yourself - all the things your friends have complimented you on. This helps you
realize how beautiful you really are.
10. Express you creative self. Do things for fun - instead of competing or trying to be perfect! Have fun expressing your personality through crafts, sewing, cooking, decorating,
gardening or anything else that helps you feel happy. Know that you are unique and express it!
Summary - one positive step at a time
Developing a positive body image is a gradual process. Relax, take your time, and congratulate yourself every step along the way as you learn to accept you body. And remember...enjoy eating well, being active
and feeling good about yourself.
REMEMBER TO WASH YOUR
HANDS BEFORE LEAVING THE
WASHROOOM AND REDUCE THE
RISK OF SPREADING GERMS!