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DDEES, LLC & Full Circle Quality. Don Dees CEO & President Cell: +1 ( 616) 902-2894 ddeeshome@ aol.com. Web Site: DDEESLLC.com & Web Site: FULLCIRCLEQUALITY.com. Full Circle Quality performs the following: 1. Consulting Services Coach to implement & sustain Quality Systems
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DDEES, LLC &Full Circle Quality Don Dees CEO & President Cell: +1 (616) 902-2894 ddeeshome@aol.com Web Site: DDEESLLC.com & Web Site: FULLCIRCLEQUALITY.com
Full Circle Quality performs the following: 1. Consulting Services Coach to implement & sustain Quality Systems LEAN Manufacturing Processes Problem Solving General Management/Leadership Processes Stamping, Welding, Plastic Injection Molding, Painting, Assembly Material Handling & Logistics 2. Inspection/Sorting and Containment Sorting/Containment Incoming Inspection Vehicle Inspection Statistical Sampling Root Cause Analysis General Rework of parts 3. Assistance in Hiring Technical Experts Hire North Americans with Specific Skills to Help in China or in NA 4. Training Quality Systems LEAN Manufacturing Problem Solving Leadership Technical Training We have over thirty (30) Professional Team Members with Manufacturing Experience of over 25 years per person. We have a team of Technical Experts (Process Engineers) with years of experience with Automotive OEM’s, who can help you solve any of your Stamping, Welding, Plastic Injection Molding, and Painting issues. We specialize in Quality and LEAN. We also perform Third Party Inspection & Repair Services. We have People who can Train your Team on all of the subjects listed above. Don DeesMobile: +1 (616) 902-2894Email: ddeeshome@aol.comWeb Site: DDEESLLC.comWeb Site: FULLCIRCLEQUALITY.com
DDEES, LLC FULL CIRCLE QUALITY, LLC Don Dees • CEO & President • Consulting Company of Professionals that assists Chinese and NA Companies • Quality & LEAN Manufacturing • Third Party Inspection & Containment of Suspect Poor Quality Parts • Training • Technical Assistance • Contract Employees • “Headhunter” Assistance • Vice President of Quality • Vice President of Manufacturing • $1 Billion savings per year from improvements in warranty • Instituted Commonization of Vehicle Sub-Systems and Components; thus saving DaimlerChrysler an additional $2 Billion per year. • Proven Lean Operations & Implementation Experience: • (Trained from the “floor up”) • Trained by Toyota in Japan (Best Japanese TPS trainers in the World) not by book, theory, or consultants. • Applied Lean Knowledge by starting up New Toyota Plant. (1stYear it won JD Power) • Ground up plant launch: Toyota Hiring Process, Developed the TPS Training & Trained the first 600 TM’s, Launched the Plants(2), Improved NA Suppliers w/TPS • I have implemented these LEAN/TPS tools in OEM’s (GM, DaimlerChrysler & Hyundai), Supplier Companies (BHM Technologies, China), and NON-Automotive Companies (Deere, Cat & China Suppliers); in Both Union & Non Union Environments and in Countries & Cultures across the World. • Proven Ability to Find Talent, Develop Leaders, Teach & Coach, Develop a Great Team, and Get Results • Multiple Success Stories in many different Cultures & Countries • Experience with aspects of corporate financing & restructuring • Successful in New Business Start-ups • Successful in Sales & Marketing USP Products • Successful in Innovating New Products & New Markets • Experience in B2B, B2C, Wholesale, Retail, Dealerships & Aftermarket • “PROVEN CHANGE AGENT” • CEO & President • Private Equity • Three (3) Portfolio Companies • Ten (10) Manufacturing Plants • $400M in Sales Revenue • Annual ongoing cost savings • of over $17M per year • $20M of cash generated from reducing inventory levels • New Product & Markets • Top American Leader • Developed the TPS Training Materials & Trained the TM’s • Director of Paint Engineering • Plant Manager • Experience includes: • USA & Canada • Germany • England • Japan Donald (Don) Dees Mobile: +1 (616) 902.2894 Email: ddeeshome@aol.com Web Site: DDEESLLC.com Web Site: FULLCIRCLEQUALITY.com • Vice President of Quality & Service • Hyundai Quality improved to the top • #1 non-luxury vehicle nameplate • Started Service Contract Business • Started Certified Used Car Program
Examples of Improvementsmade Before & After LEAN Manufacturing Example of a Project just completed in China Results! Our clients are obtaining results of between 17 and 35 ROI. In other words, for every dollar spent implementing LEAN, they are saving 17 to 35 times this amount of money the next year.
Results from LEAN Manufacturing Project (8.5 Month Project) • Safety • Have now gone over 200 Days in a row without any Safety Accidents in the Plant(s) • Quality (Customer) • Went from 1,000 PPM’s to Zero PPM’s & Zero QIR’s for six (6) Months in a row • Went for Last Place (#16 in 4/2011) to First Place (#1 in 4/2012) in Suzuki’s Ranking of Stamping & Welding Suppliers in China • Went from being on the “NOT allowed to Bid on New Work List” (because of past performance and lack of quality processes) in Q3 of 2011 to “Preferred Supplier List” in April 2012 with Suzuki, Chang An, JCI, LEAR and other Customers. • Quality (Internal) • Went from Checking & Repairing 300% of the parts to 0% Checking & Repairing of the parts on eight (8) totally different Final Assembly Part Numbers (IP Cross Car Beam, Seats, Steering Column Support Bracket, Radiator Assembly, Engine Tubes, Others) • Delivery • 100% On Time Delivery for six (6) months in a row • Eliminated the need for a Third Party Warehouse for Finished Goods • Eliminated 33% of the Inventory ($4M USD) • Cost • ROI of 17 Times what was spent to Implement LEAN Manufacturing • Saved Manpower, Space, Scrap, Inventory, Needs for new Capital Equipment, Others
Before LEANSafety Chain IssueWall needs RepairedWood in the Window
Parts on Floor Before LEANParts on FloorHose on Floor100% Inspection & Repair
After LEAN Safe Work Heights Safe Standardized Work Practices Zero Inspection & Repair Zero Quality PPM’s to Customer
LEAN Manufacturing Safety Tools (at employee entrance into the plant) The light is “Green” if there have been no accidents or no near misses during the past two (2) days.
Bigger Hammer Before LEANPoor Work Position & Parts on the FloorRepair with a Hammer 100% of the Parts into Correct Shape 100% Inspect & Repair
Quality Samples & Gages After LEAN
Implemented Error Proofing (Air into Weld Nuts to prevent weld balls getting into the threads)
Before LEAN“Pearl Diving” into Big Boxes NO FiFONo Pull System for Material Scheduling
After LEAN JIT Small Packaging FiFO “Pull System”
零件A After LEAN JIT Small Packaging FiFO “Pull System”
Original Situation had 40 steps in the “Total Process” before LEAN
Original Situation had only 15 steps in the “Total Process”after LEAN
Implemented Cost Reduction by Designing Stackable Rack(s) with Wheels (to move with a tugger instead of a Fork Truck)